How To Cut Aluminum Balusters

There are a few ways that you can cut aluminum balusters. You can use a hacksaw, a power saw, or a miter saw.

How To Cut Aluminum Balusters

There is no one definitive way to cut aluminum balusters. Some possible methods include using a hacksaw, coping saw, or power saw. It is important to take into account the thickness of the baluster and the saw blade when making your cuts.

-Tape measure -Paint pen or pencil -Circular saw -High-grit sandpaper -Stain or paint -Brush or rag

  • Using a hacksaw, cut the baluster along the marked line
  • File off any rough edges with a file
  • Measure the baluster to be cut and mark with a pencil

below: The balusters are going to be cut to size, so you need to measure and mark the cuts. Make sure to cut on the outside of the marks to give yourself a little room for error. The easiest way to cut aluminum balusters is with a hacksaw. Just be careful not to let the blade slip while you’re cutting.

Frequently Asked Questions

What Can I Use To Cut Thick Aluminum?

There are a few different ways that you can cut thick aluminum. One way is to use a hacksaw. Another way is to use a drill with a cutting bit.

Can I Use A Miter Saw To Cut Aluminum?

Miter saws can cut aluminum, but the blades will wear down more quickly than when cutting other materials.

What Is Best For Cutting Aluminum?

Some people recommend using a Tungsten-Carbide blade for cutting aluminum. Others recommend using a blade with a higher tooth count, like an 80 tooth blade.


Cutting aluminum balusters is simple and can be done with a few basic tools. First, use a tape measure to mark the length of each baluster on the railing. Next, use a hacksaw or bolt cutter to cut the balusters to size. Finally, use a file or sandpaper to smooth any rough edges.

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