Can You Cut an Aluminum Deck Railing? (Things You Need To Know)

Are you looking to tackle your aluminum deck railing this weekend? You’re probably wondering whether you can cut them at home, right?

Luckily, you can cut aluminum deck railings relatively easily with tools you likely already have (especially if you’re an avid DIYer). So, provided you follow the age-old saying, “measure twice, cut once,” you shouldn’t have any mishaps when sawing your aluminum deck railings at home.

Let’s take a closer look at the tools needed and the steps you should take to effectively (and accurately) cut aluminum deck railing yourself. We promise you don’t need to splash the cash on expensive equipment.

You Don’t Need Specialist Equipment to Cut an Aluminum Deck Railing

At first glance, you might think cutting aluminum is near-on impossible from the comfort of your home. But thankfully, that is far from the truth.

Despite its seemingly complicated nature, with a good miter saw and a high-quality blade, you can cut through these railings in a matter of moments. See? No specialist equipment is necessary.

And yes, even professional contractors recommend this method! So, let’s move on to the best saw and blade for the job.

The Best Saw and Blades For Cutting Aluminum Deck Railings

You need a miter saw for best results when cutting aluminum deck railings. Most DIYers we know already have one, but if you haven’t yet jumped aboard that particular bandwagon, we suggest the following brands (they provide excellent value for money):

Bosch
DeWalt
Milwaukee (particularly the cordless miter saw)
Makita
Skilsaw
Ryobi (we highly recommend the TSS103 for homeowners and hobbyists)

Once you’ve acquired the miter saw, it’s time for the most critical part — selecting the correct blade to make cutting aluminum deck railings as easy as possible. Technically, diamond blades are the best for cutting aluminum. However, they are pretty expensive. So, we recommend one of the following cheaper blades to ensure perfect yet budget-friendly cuts every single time: (affiliate links).

MASTEC 10-inch 100T Aluminum Saw Blade — The MASTEC blade cuts through aluminum like butter. The triple chip teeth ensure a clean edge while providing the durability needed for heavy-duty jobs. In addition, it comes with a 100% replacement guarantee. But just keep in mind that it may create more dust than other blades on our list.
Diablo D1080N Non-Ferrous Metal Blade — Compared to the other blades, it has a reasonably high price tag. However, it’s made from micro-grain titanium carbide and weighs a mere 1.45 lbs. Plus, it allows you to cut all sorts of metal, making it useful for other projects. You’ll also benefit from laser-cut stabilizer vents for superior ventilation.
Evolution Aluminum Cutting Saw Blade — The carbide tooth design prevents clogging and keeps the cutting action smooth. From remodeling projects to automotive repairs, this blade is recommended for all types of projects. It’ll no doubt become a staple in your workshop long after you’ve finished cutting aluminum deck railings. It’s wallet-friendly yet performs like it costs the earth. You can’t ask for more than that!
TWIN-TOWN 10-Inch 80 Tooth Saw Blade — Like the Diablo blade, TWIN-TOWN’s model has laser-cut stabilizer vents to trap vibration and noise, preventing warping. The C4-grade tungsten carbide construction offers a life twice as long as the others. It’s easy to use, even without experience, allowing you to blaze through your deck project. However, it tends to be noisier than most.
DEWALT 6-½-Inch Aluminum Cutting Saw Blade — This super-thin kerf blade is precision balanced to guarantee accurate cuts every time. Plus, the hard carbide tips decrease the likelihood of wear and tear. Not to mention the laser-cut expansion slots reduce noise output and vibration for fewer burns and perfect surface finishes. Although, it typically comes with just a one-year warranty.

How to Cut Aluminum Deck Railings Easily

Okay, you’ve secured all your equipment by now, so it’s time to get cutting. But first, we need to touch on safety.

A Quick Note on Safety

We know you’re itching to get started. But make sure you have the basic PPE (personal protective equipment) before jumping into the project.

You should wear safety goggles (flying metal shards and eyes do not mix) and gloves. Put these on and you’re ready to follow our step-by-step tutorial on easily cutting aluminum deck railings.

Your Step-by-Step Tutorial For Cutting Aluminum Deck Railings

Find a surface — Put the aluminum rail on a flat, hard surface. Choose somewhere you don’t mind covering with debris and potential scuffing. You could simply place it on the ground! Some people decide to buy a miter saw stand, but that isn’t necessary if you only need to cut a few aluminum deck railings.
Weigh it down — Place a sandbag (or something similar) on both ends of the railing to ensure it doesn’t roll while you’re sawing. If you’re using a proper stand, clamp the railing down instead.
Measure — Use a tape measure or ruler to make where you need to cut. As we said earlier, measure twice and cut once. That way, you won’t waste material with inaccurate measurements!
Mount the blade — Remove the current miter saw blade and insert your aluminum-specific one. Do this by opening the blade guard.
Saw the railing — Place the miter saw on the spot you need to cut. Ensure it’s perpendicular to the railing for a straight incision. Keep one hand on the railing and use your other hand to lower the miter saw handle until it touches and cuts the metal. Once you’ve sliced all the way through, lift the handle and remove the railing.
And et voilà — It’s time to celebrate! You’ve successfully cut the aluminum deck railing with a miter saw! Keep going to finish your project and marvel at your hard work.

The Bottom Line

Cutting aluminum deck railing at home is simple when you know how. By following our step-by-step tutorial and adhering to basic safety protocols, you’ll complete your project with no difficulty. Just always remember to measure twice and cut once for the best results!

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