How To Cut Aluminum Siding

How To Cut Aluminum Siding

With aluminum siding becoming a popular fixture in different homes, learning how to make them can be a potentially nice skill. The problem is that it is not as easy as most people might expect. It will take precision, hand skills, and attention to detail to get this done right. Here is the process of how to cut aluminum siding.

Why Aluminum Sidings are Popular?

Aluminum as a siding material is quite popular because of its superior aesthetics. Provided you use high-quality aluminum, it will look good in just about every kind of home, regardless of design or theme. When used as a component for renovation, it can radically transform the look of your property.

Aluminum sidings are most popularly used in window and door frames, while it can conceivably be used anywhere in the house. They are most commonly found in houses that use a lot of aluminum, which helps in achieving both an aesthetic and functional look.

Can You Do This Yourself?

How to Cut Aluminum Siding


Your inner handyman desires to construct most (if not all) of your house using your bare hands. Many people, especially those who think that they have a lot of DIY experience under their belts, believe they can do the cutting themselves. However, there are some problems that should be dealt with.

The biggest issue is how challenging cutting aluminum can be. You need to make sure that all measurements are on-point before you can even make the first cut. As for the process of cutting through the metal itself, it can be described as something that requires your full attention.

Learning how to cut aluminum siding is not going to be easy. You would need a bunch of tools (see more) and an exacting approach is needed. However, you don’t really need to have expert level skills to complete this job yourself. The following is a simplified guide on how to cut aluminum siding.

Materials and Tools Needed

  • Aluminum siding
  • Underlayment material
  • Sealant
  • Nails
  • Pencil or Chalk
  • Ruler
  • Protractor
  • Power saw (with panel blade)
  • Tin snips


Cut Aluminum Siding


1. Preparing the Area

  • Before you even think of putting a new siding in place, it is crucial that you clear out the area where it’s going to be installed. Remove the old siding. The technique here depends on the type of old siding you have, but you can get the help of a professional if this proves to be too complicated for you.
  • After removing the old siding, you must prepare the area where you’ll be installing the new siding. Clean the surrounding wall as any excess dirt can cause the underlayment and sealant to not bond properly. Any excess paint or putty should also be removed. Any protruding item such as nails should be removed or flattened. Any dent or hole should be filled with putty or sealant.
  • After cleaning up and fixing the bare wall, you can then install your choice of underlayment material. The most common underlayment used with aluminum is foam board, though you are free to use other materials if you see it fit. Underlayment should be installed properly to prevent the formation of gaps.
  • Install the corner posts and footer. These are pieces of trim that will serve as part of the framework of not just the siding, but also of the borders of the door or window. Take note of the measurements of the corner posts and footer, as it is essential for the proper placement of sidings. Apply sealant at the corners to ensure an airtight seal.

2. Making the Measurements

  • Because of the inherent brittleness of aluminum, it is a risky approach to just haphazardly cut up the sidings. It is important that you make the proper measurements first before you start cutting.
  • Measure the dimensions of the area where you will be installing the sidings. Ideally, the siding should fit flush into the edges of the door/window frame. These measurements would then serve as your basis for cutting into the sheets.
  • Using these measurements as a guide, draw up lines in the aluminum based on the measurements as your guide for cutting.

3. Cutting the Sidings

  • Using the guide lines that you drew using the pencil or chalk, cut the sidings according to your measurements. For cutting large pieces of siding, you can use a power saw. The most recommended blade for the job is the panel blade because it cuts through aluminum without tearing or snagging.
  • For making smaller cuts where using a saw would be too cumbersome (ex.: when cutting at the edges), cutting using tin snips is a better option. This provides you with better control in making small cuts, ensuring uniform cutting with no damage on the aluminum.

4. Installing the Sidings

  • Once you have completed the cutting, the next step is to install the sidings in their respective places. Before going for the installation, make sure that each piece fits exactly where they should be. Otherwise, you will have to go back to step 3 to ensure that you arrive to the necessary dimensions.
  • Once all dimensions are deemed to be correct, it is time to install the sidings. When installing sidings on windows or floors, it is best to start at the floor to minimize the potential of leaks. After installing the floor sidings, you can install the sidings on the opposite corners, and then install the sidings on the top.
  • Secure in place by attaching nails into the nail strips found at the sidings. You don’t have to place the nails too deep as the sidings are intended to hang in the nails rather than be nailed on place.
  • Finish all sides of your project one by one. When it is necessary to use more than one siding to complete one row, overlap each successive panel by 1 inch. Once installation is completed, add sealant at the corners and gaps to ensure an airtight fit.

Aluminum siding is a popular and reliable material used for installing on homes. Whether you’re a DIY enthusiast or a professional contractor, you may need to cut the aluminum siding to fit around windows and doors or to make custom contours. In this guide, we’ll show you the best ways to cut aluminum siding using different tools such as chop saw, saw blade, utility knife, and tin snips. Safety is always a priority, so make sure you wear gloves and safety goggles before you start cutting. Choose the right blade for your saw and use the power tool or tin snips with caution to avoid damaging the blade or causing metal shards to fly. Cutting aluminum siding can be easy and efficient, so let’s get started on your siding project.

Choosing The Right Tool For Cutting Aluminum Siding

When it comes to cutting aluminum siding, choosing the right tool is crucial for getting a clean and precise cut. There are several tools available for cutting aluminum siding, including power saws, tin snips, and utility knives. Each tool has its own strengths and weaknesses, and the best tool for you will depend on the type of cut you need to make. For example, a power saw is ideal for making long horizontal cuts, while tin snips are better for cutting the contours of the aluminum siding around windows and doors. When using a power saw, it is important to choose a panel blade specifically designed for metal cutting, and always make sure you wear gloves and safety goggles for protection. On the other hand, tin snips allow for more control and precision, but can be tiring to use for long periods of time. Ultimately, the choice of tool will come down to personal preference, but it is important to choose a tool that is designed to cut aluminum without damaging the blade or causing metal shards to fly.

Cutting Aluminum Siding With A Circular Saw

Cutting aluminum siding with a circular saw is a quick and efficient way to make precise cuts. Whether you’re cutting aluminum siding to fit a piece around a window or to cut the width of a panel, a circular saw is a versatile tool that allows you to make straight cuts with ease. To get started, you’ll need a metal cutting blade specifically designed for cutting aluminum. It’s important to set up the saw properly, making sure it’s cutting horizontally, and to guide the blade slowly and steadily through the siding to ensure a clean and accurate cut. It’s also important to wear gloves and safety goggles to protect yourself from metal shards while making the cut. When installing aluminum siding, using a circular saw can save time and effort, and can result in a smooth and professional-looking finish.

Using A Miter Saw For Precise Angle Cuts

A miter saw is a power tool that is commonly used for making precise angle cuts in a variety of materials, including aluminum siding. When using a miter saw to cut aluminum siding, it is important to use the proper blade and to set the saw up correctly to ensure accurate and safe cuts. Before you begin, make sure that you have the proper safety equipment, such as safety glasses and gloves, to protect yourself while cutting. You may also want to use a straight edge or a guide to help you keep the saw blade straight and on track as you make the cut. When making the cut, it is important to go slow and steady, taking care not to force the saw through the material too quickly, as this can result in a poorly cut edge. By using a miter saw and following these tips, you can ensure that you make precise and accurate angle cuts in your aluminum siding, helping you to achieve a professional-looking result.

Cutting Aluminum Siding With Tin Snips

Tin snips are a good choice for cutting aluminum siding. They are designed to cut through thin metal sheets and can be used to make precise cuts in aluminum siding. Before using tin snips, make sure you choose the right type of snips for the job, such as red-handled tin snips for cutting aluminum. To use tin snips, place the piece of siding in a secure place and hold it firmly in place. Make sure to wear gloves to protect your hands from the sharp edges of the metal. Slowly and carefully make the cut along the top edge of the siding, following the contours of the material. Be careful not to apply too much pressure, as this could result in a poorly cut piece of siding. Tin snips are a reliable tool for cutting aluminum siding, and will help you make precise cuts around windows and other obstacles.

Using An Angle Grinder For Cutting Metal

An angle grinder is a power tool that can be used for cutting aluminum and other metals. Before using the angle grinder, make sure you are wearing safety gear, such as eye protection and gloves, to help protect you from debris. Choose a metal cutting blade for the angle grinder, and make sure it is tight and secure. Set up the angle grinder and the material you want to cut, making sure it is securely in place. Begin cutting slowly, allowing the angle grinder to do the work for you. It’s important to use a steady hand and guide the blade, as this will result in a cleaner and more precise cut. Make sure to use proper techniques and to work carefully to avoid damaging the material or yourself.

Tips For Making Long, Straight Cuts In Aluminum Siding

When cutting aluminum siding, it’s important to make sure you have the right tools and equipment to make a long, straight cut. Using a power saw, such as a radial arm saw or a power miter saw, is typically the best way to make straight cuts in aluminum siding. Before you begin cutting, make sure you have the right blade installed and the saw is set up properly. It’s also a good idea to make sure the siding is held securely in place, either by using clamps or by having a helper hold it for you. When cutting the siding, be sure to cut slowly and carefully to avoid any mistakes. If you need to make cuts around windows or other obstacles, you can use tin snips or a sharp utility knife to make the necessary adjustments. With the right tools and techniques, you can easily make long, straight cuts in aluminum siding to achieve a professional-looking result.


In conclusion, when you need to cut aluminum siding, it’s important to choose the right tool for the job. A circular saw can be used for making straight cuts, while a miter saw is best for precise angle cuts. Tin snips can also be used for cutting aluminum siding, but they are best for smaller cuts. An angle grinder is a good option for cutting metal, but it should only be used by those with experience. Regardless of the tool you choose, it’s important to take your time and make sure your cuts are straight and precise to ensure the best results.

Frequently Asked Question (FAQs)

If you’ve still got questions about How to cut aluminum siding, then these may help:

What Is The Best Tool To Cut Aluminum Siding With?

A power saw, such as a circular saw, is the best tool for cutting aluminum siding. Tin snips can also be used, but may not be as efficient for making long cuts. Before using any cutting tool, it is important to make sure it is properly set up and that you have the appropriate safety gear, such as protective glasses and gloves.

How To Cut Aluminum Siding Around Windows?

To cut aluminum siding around windows, you can use either tin snips or a power saw. Tin snips are handheld tools that are designed for cutting sheet metal and are ideal for making small, precise cuts in aluminum siding. Power saws, such as a radial arm saw or a jigsaw, are more suitable for making longer, straighter cuts and can be used to quickly and efficiently cut aluminum siding around windows. Before you begin, make sure you have the proper safety equipment, such as gloves and eye protection, and that the siding is securely in place to prevent it from moving while you make your cut. To ensure a straight cut, you can use a straight edge as a guide or make marks on the siding to indicate where to make the cut. Finally, always cut slowly and deliberately to prevent damaging the siding or injuring yourself.

How To Cut Aluminum Siding For Door?

To cut aluminum siding for a door, you can use a power saw, such as a circular saw or jigsaw, or a hand tool like tin snips. Before starting, make sure to measure and mark the siding where you want to make the cut. To use a power saw, set it up with a blade suitable for cutting aluminum, put on protective gear such as safety glasses, and make sure to hold the siding securely in place while cutting. When using tin snips, choose a pair of red or green handled snips and make sure the blade is sharp. Cut slowly and steadily along the marked line, using the guide edge of the tin snips to keep the cut straight. Keep the siding in place and make sure to work in a safe, controlled manner to prevent any accidents.

Can You Cut Aluminum Siding With Oscillating Multi Tool?

Yes, an oscillating multi-tool can be used to cut aluminum siding. However, it may not be the best option for making long, straight cuts, as it is designed for more intricate or detailed cutting tasks. For large cuts in aluminum siding, a power saw or tin snips might be a more efficient choice. When using an oscillating multi-tool, it is important to choose the right blade and to follow the manufacturer’s instructions to ensure a clean, accurate cut.

Can You Use A Wood Blade For Cutting The Aluminum Siding?

No, it is not recommended to use a wood blade for cutting aluminum siding as it will not be able to effectively cut through the metal material. Aluminum siding is a harder material and requires a blade specifically designed for cutting metal, such as a metal-cutting blade, to ensure a clean and accurate cut. Using a wood blade can result in a rough and jagged cut, and may also cause damage to the blade.

Krystal Morrison

I create this blog to share my daily tips about home improvement, children, pets, food, health, and ways to be frugal while maintaining a natural lifestyle. Interested to be a Guest Blogger on my website? Please email me at: [email protected]

Click Here to Leave a Comment Below 0 comments

There are affiliate links in this post. At no cost to you, I get commissions for purchases made through links in this post.