Cutting metal

[Kurt_]

What's the best way to cut a nice, straight line in really hard, brittle, metal sheets?

How about cutting 1/16" aluminum?

I'm looking for a nice professional cut, but nobody in my family has any metalworking experience. All we have is a hacksaw, an un-mounted wobbly bench grinder, and no knowledge of metalworking tools beyond said hacksaw or grinder.

I think I'm looking for a table-mounted (or table-sitting-on-ing) unit more than a hand-held device, and it needs to have the option of using diamond-tipped blades.

[nevermind1534]

Dremel?

[bacteria]

No, dremel can cut metal but is very dangerous. I have cut metal sections and been fine, but any slip can be bad!

1/16" is fairly thin, how about using a screwdriver to score a line the length, then vice the metal between wood, and bend the metal back and forth until it snaps off; then use a dremel to sand the metal sharp bits off - a grinding stone should do the job.

[XCVG]

A jigsaw with a metal blade would work but be messy. A shear would work but be expensive. Go with bacteria's method.

[Kurt_]

Yeah scoring sounds about right. It might not be perfect but it's better than cutting it with shears (=bent aluminum).

Now, how about cutting a 105mm x 105mm x 2.7mm sheet of tungsten carbide into 1" strips?