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G'day all,

I want to make some magnetic movement bases. Well, the models are magnetic, so I just need a sheet metal movement tray.

Question is, how do you cut sheet metal neatly at home, and what thickness?

At work I used to cut sheet metal to a rough size using a big guillotine, then use a linishing belt and grinding wheel to finish it off. I have neither of those things at home and I don't really want to buy them as I have no room in the garage. Also laser cutting was nice, but not really practical for just cutting a few movement trays.

Any suggestions?

Tin snips would be the cheapest option...

If you have a dremel, then the grinding wheels should be fine for thin metal sheet, but you might not get a very straight line.

Look for straight cut snips, the handles are usually yellow. Left or right cut snips will work, but it's harder to cut straight with them and often leaves the cut pretty jagged.

There are other snips designed for cutting flat sheet metal, they look like big scissors and have longer cutting blades than standard "aviation" snips.

A good saw will serve you better, snips will bend the metal.

Yeah I cut a steel sheet with tin snips & it took me ages to get it roughly flat again - had to use a vice.
I recommend find some flexible metal sheet such as this:
http://www.first4magnets.com/a4-sheet-magnets-c81/flexible-a4-magnetic-sheet-with-3m-self-adhesive-297-x-210-x-0-85mm-p3480
It's what I used in the end for my other tray & was so easy to cut then stick on to the tray.

Snips are about the easiest way...glue it down quick though, lest you loose a finger. The edge will be very sharp.

You might call up a sheet metal shop. A break would make short order of it, and you will have a much cleaner cut. Most that I have dealt with are willing to do that for pretty cheap.

 bubber wrote:
Yeah I cut a steel sheet with tin snips & it took me ages to get it roughly flat again - had to use a vice.
I recommend find some flexible metal sheet such as this:
http://www.first4magnets.com/a4-sheet-magnets-c81/flexible-a4-magnetic-sheet-with-3m-self-adhesive-297-x-210-x-0-85mm-p3480
It's what I used in the end for my other tray & was so easy to cut then stick on to the tray.

How strong is that? I've always found that rare earth magnets on a flexible magnetic sheets are quite weak compared to rare earth magnets against a steel sheet.

Use a hacksaw and clamp the piece down to a solid surface (thin metal will flex and chatter like crazy, otherwise) if you're worried about the material curling. Personally, I'd just use snips and clean up/straighten out the edges, as necessary, but I'm also very comfortable working sheet metal with hammer and files, which not everyone is. Really isn't particularly difficult, but it is an additional step.

As for thickness, it doesn't take much to attract a magnet. 28g galvanized steel (ducting or roof flashing) should be more than sufficient for most trays. I wouldn't try lifting metal cavalry by the corner of the tray, of course, but it won't flex under a block of 20 plastic troops, especially if you add a stiff rim or laminate it over HIPS or MDF.

AllSeeingSkink wrote:

 bubber wrote:
Yeah I cut a steel sheet with tin snips & it took me ages to get it roughly flat again - had to use a vice.
I recommend find some flexible metal sheet such as this:
http://www.first4magnets.com/a4-sheet-magnets-c81/flexible-a4-magnetic-sheet-with-3m-self-adhesive-297-x-210-x-0-85mm-p3480
It's what I used in the end for my other tray & was so easy to cut then stick on to the tray.

How strong is that? I've always found that rare earth magnets on a flexible magnetic sheets are quite weak compared to rare earth magnets against a steel sheet.

it's been strong enough for me & i'm not even using rare earth on the models just magnetic tap cut to fit (http://www.first4magnets.com/tape-strip-magnets-c85/12-7mm-wide-x-1-5mm-thick-magnetic-tape-with-premium-self-adhesive-p3525 - like this but thicker). It's not as if you're going to play Frisbee with it

Well I would like to be able to use it for transportation, so the flexible sheet probably doesn't have enough strength to it.

How think of a sheet?

If all else fails you could take a very thin piece and glue it to a substrate like plasticard or MDF to give it the rigidity.


They also make benchtop breaks but wouldn't think it would be practical unless you where made of money or where making these en-mass.

I used an electric saw with a debris blade on it to do mine. O laid it on a piece of scrap wood to stop it bending and it worked a treat. I used a compound angle mitre saw, but a jigsaw would work fine too.

Also, I did a tutorial here if you are interested!

http://www.dakkadakka.com/dakkaforum/posts/list/502033.page#5198611

For transport I put my models in a steel tool box I picked up.