How to Cut Corrugated Metal Roof Panels

Corrugated roof panels come in a premeasured lengths and widths that may not always match your needs. You can use readily available power tools to cut through the panels, whether you need to cut along or against the corrugated channels. Metal cutting does leave behind dangerous shards, so cut in a dedicated area when possible, and always sweep up the metal filings afterward.

1. Measure
   the corrugated metal panel. Lay a board or yardstick on the panel and mark
   the potential cut line with a permanent marker.


2. 
   

   Turn
   painted panels upside down before marking and cutting them. In doing this, the
   bottom of the panel is far less likely to experience paint damage during
   the cutting process.

   
   


3. 
   

   Place
   a pair of steady boards on either side of the cut line. Secure the boards and the
   metal panel to a sawhorse on both sides of the cut line as well. The
   sawhorses elevate the panel to a proper working height, while the boards
   hold the panel down and even so it doesn't bend or warp as you cut through
   it.

   
   


4. 
   

   Insert
   a metal-cutting blade into a reciprocating saw. Always wear heavy gloves,
   long sleeves and eye protection when cutting through the metal.
   Cutting through metal is noisy, so ear plugs are also recommended.

   
   


5. 
   

   Cut
   through the panel along the line using the reciprocating saw. It may
   be necessary to replace the blade frequently if you are cutting
   through multiple panels.

   
   


6. 
   

   Use
   a metal file to smooth the edge of the cut line and remove any burrs
   that formed from the saw blade passing through.