You almost have it right. Clamping thin metal between two MDF sheets
(preferably with fasteners all-round the sheet, except at the cut line)
works fine.

Keep your (many-toothed) carbide blade fast. Wear full-face protection AND
glasses underneath, and consider a stout bib, like a welder's apron for hot
chip protection (the stuff HURTS).

This isn't the best way. Try a sheet metal shear G.

BTW... It's not easy on the operator, neighbors, or equipment, but I've
resorted to cutting up to 1-1/4" aluminum plate on an ordinary table saw.
(don't have a plasma cutter). It's slow, painful, and noisy. But 'twerks
fine. It even produces a nice cut, if the work is guided accurately, and
the blade is strong enough not to flutter.

LLoyd

wrote in message
oups.com...
i was wondering if it was possible to make straight cuts in 26 -22 ga
steel (zinc coated and otherwise) with my table saw. i was planning on
using a 3/4" plywood or mdf sled with toggle clamps as hold down. it
seems kinda obvious that this kind of support would be necessary for
nice clean cuts without bending the crap out of the relatively thin
metal. my question is, is this even possible with ANY blade on a table
saw? i have NO idea what type of blade would cut the metal safely.
can anyone recommend anything besides shears? i've tried and they just
didnt cut it.... no pun intended. ok maybe it was. =)
thanks
handsome greg