Need safety tips for cutting corrugated metal roofing - almost lost a finger!

Hey Tool Discount Club folks, I'm working on my shed roof and need to cut some corrugated metal panels to fit around a vent pipe. Last time I tried this with tin snips, the metal buckled and I nearly sliced my hand open. What's the safest way to cut this stuff without ending up in the ER? I've got an angle grinder, circular saw, and jigsaw available. Thanks in advance!

OP, STOP right there! Do NOT use that angle grinder on thin corrugated metal unless you want shrapnel in your face. I've seen guys in the shop try that and end up with metal flakes embedded in their safety glasses. For precision cuts, use aviation snips (the red ones for left curves, green for right, yellow for straight) and go slow. Support the panel fully so it doesn't flex. If you must power-cut, put a fine-tooth metal blade in your jigsaw and clamp everything down tight. And for God's sake, wear leather gloves and full-face protection.

Larry's spot on about the grinder danger - that's like asking for a trip to sparky heaven. Here's my two cents from electrical work: those panels can have sharp burrs that'll give you a nasty cut plus potential tetanus. After cutting, always file or deburr the edges. Also, if you're working on a roof, make sure you've got proper fall protection. No project is worth a broken neck. I'd take the extra time to use hand tools rather than risk a power tool kicking back on a ladder.

Ugh, metal roofing is the worst! When we have to cut it for drywall backing, we always use a circular saw with a ferrous-metal blade (look for one with 60+ teeth). Put the panel GOOD SIDE DOWN on sawhorses with foam insulation underneath to prevent vibration. The key is letting the saw do the work - don't force it. And yeah, what Mark said about deburring! I've gotten more cuts from 'finished' edges than the actual cutting. Also, ear protection - that screech will make you jump and lose control.

All good advice! From HVAC perspective: we cut similar corrugated duct all the time. If you go the power tool route, attach a shop vac to capture the metal dust - breathing that garbage will wreck your lungs. Also, watch where the sparks go if using any abrasive method. Had a coworker start a roof fire from grinding near old tar paper. Honestly? For one shed project, I'd just use the aviation snips Larry mentioned. Takes longer but zero chance of losing digits. Post pics when you're done!