coppertop4646

Can I use a jig saw to cut a window in my side panel as long as the blade has a high number of TPI

XedLos

It should be fine but you will have to have some sand paper to clean off the edges. Plus i would recommended to have something under the case so you dont just cut the metal panel. maybe some wood under will help you get a cleaner cut and not mess up in the cutting.

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coppertop4646

yeah i was thinking of doing something along those lines with the wood

XedLos

yeah put some ply wood under it and you'll be fine. Also put painters tape over the entire side panel to have a cleaner cut.

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iandroo888

use some 2x4's or something to "lift up the panel a few inches off the table or ground. if anything, use an empty box. any tpi over 20 imo is good enough.

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radodrill

You want to have the area around the cut well supported; having wood directly under the cut will make it more difficult to cut, so just use 2x4s or something similar to support it within 1" on the cut. What is also very useful is to have the panel clamped down to the worktable as tis will prevent it from moving during the cut and allow you to produce a cleaner cut. Once you've completed the cut, you'll want to use a fine metal file to de-burr the cuts.

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CattleRustler

also, a technique I use is to cut the corners of the window with a holesaw, giving nice clean arcs thru the corner, then join those with simple straight cuts. If you plan to c-channel the cut make sure you use a holesaw with some size to it (> 2"), anything smaller will make it difficult for the channel to bend and stay in place without some gluing or other nasty business

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MNiceGuy

I use a jigsaw with variable speed so I can dial it down a little. Depending on the material, I'll use either a 24tpi or 32tpi blade. As others have said, use something to prop under your work and if at all possible, fasten it down. That is going to really help your chances of getting a nice, clean cut. Take your time and everything should work out!

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drjoey1500

i would recommend sawhorses or 4x4's to rest it on. also clamp it down as previously suggested if at all possible to stop it from running away. i have some metal jigsaw blades, sry i dont remember exactly the specs, but they are like cobalt tipped or something. anyway they really tear through thin metal. the TPI suggested before sounds about right.

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The Master Chief

When I cut the side panel for my case, I hung it over the side of the work table in our garage, clamped it down and sawed through it with 24 tpi.

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