What tools do i need to cut out 2 squares out of metal step?

[Judithvdv]

  

[Noyade]

Good morning Judith @Judithvdv 

My first thought would be a jigsaw with a metal cutting blade - and remove the metal piecemeal.

Starting with curved cuts and then the sides. A file should clean up the rest.

Or - if it's not critical - a hacksaw down the two sides and with a pair of pliers gently bend the remaining metal - up and down slowly till it fractures. Clean up with a file.

I hope this makes sense with the jigsaw cuts...

"metal step"

Thinking further - how thick is this aluminium Judith?

[Jason]

Welcome to the Bunnings Workshop community @Judithvdv.

Great to see you've received a prompt reply from @Noyade. Let us know if you need any further assistance and feel free to post anytime.

Jason

[Dave-1]

Good afternoon @Judithvdv 

I Like @Noyade's idea, I have one that is similar but may be easier.

Drill two holes at either inner point of the square.

Then using a coping saw cut from the holes outwards. Its aluminium so should cut fairly easy.

Dave

[Noyade]

Afternoon Dave! @Dave-1 

It's very hot outside - but never too hot to experiment - or learn. 😊

I've never used a coping saw on aluminium - so I tried it outside and it works remarkably well.

Less material removed compared to a hacksaw...

The 'fatigue' method I suggested does leave an edge that needs to be filed...

Holes and coping saw...

And you can easily rotate the coping saw for the final cut...

This of course is very thin aluminium - but I'm impressed mate. 👍

Cheers.

[Dave-1]

@Noyade 

ahhhh the years of modifying bits has paid off! Last time I used one was to cut cornice I had made and needed an odd angle

Thank you

Dave

[EricL]

Hello @Judithvdv 

It's great that you've received excellent advice from @Dave-1 and @Noyade. I do believe they've covered all the angles on this one. You can use a hack saw, coping saw or a jig saw with a metal cutting blade. Just to add to the suggestions made, I recommend making sure that you have a secure surface where you can clamp your step for cutting. 

Please remember to wear personal protection such as gloves, goggles and a mask when working on your project. 

If you need further assistance, please let us know.

Eric