What to use to cut Diamond Plate sheets?

[jakeru]

I can tell you that wood bandsaws run at much higher speeds (talking about feet per minute of the moving blade) than metal cutting bandsaws. It might work OK on aluminum though. I hear that generally speaking, a setup that is good for cutting hardwood, works well for aluminum too.

I've seen skillsaws used very effectively for cutting aluminum sheet in the 1/16-1/8" thick range. Clamp a straight piece of wood to the sheet to use as a guide if possible, and use a blade with carbide teeth. Might need to wear hearing protection.

I remember seeing this baby sized skillsaw (circular saw) that worked great on aluminum and was nice and compact too. Its blade was smaller diameter than most and I remember the blade being more lined up with the handle than the average one so it seemed like it wouldn't torque on your wrist and seemed a little safer to me. I wish I had that one.

[edit]
Oh, I almost forgot to add.... I know they make cutoff wheels for aluminum too. I've been meaning to pick one up to try for my 4.5" angle grinder. I have a 4.5" grinding wheel for aluminum and find it's a *really* useful tool. Normal cutoff wheels and grinding wheels are no good for aluminum though, because they load up. The kind made for aluminum seem to shed their abrasive grains more aggressively than standard grinding wheels, and at least for that reason, don't get as loaded up (and actually work.)