I have a rangehood ceiling duct cover that is too long for my use so I trimed it with cirular saw. The finished edges look rough after cutting(picture attached). There are minor dent all around the edges and the it would cut my skin. I have already tried deburring tool and had little success. Is there another tool I can use to flatten the dent and smooth out the edge? Metal edge

  • Thin metal like this can be cut with a utility knife and straight edge Multiple passes wil get you through with a smooth edge
    – Kris
    Sep 7, 2021 at 1:09
  • install it in such a way that the edge doesn't show.
    – Jasen
    Sep 7, 2021 at 2:07
  • 3
    For future reference, a circular saw is the wrong tool to use here. Ideally a nibbler would be used.
    – Ron Beyer
    Sep 7, 2021 at 3:15
  • A shear would be the ideal tool, especially since that's probably what was originally used at the factory - not necessarily a home tool unless you're doing a lot of metal work, though. A nibbler or tin snips would have been a strong second.
    – FreeMan
    Sep 7, 2021 at 11:45
  • @crip659 The Answer box for your answers, please, not the comment box! ;)
    – FreeMan
    Sep 7, 2021 at 11:46

1 Answer 1


A hammer(ball preen) and a 2x4 to flatten,and a file to smooth. Place wood on one side and tap with the hammer from the other side, change side and repeat.

Probably clamp a piece of wood on both sides when filing. Could also use an angle grinder with the two pieces of wood to give a straight edge, probably still need a file to smooth/clean up the edges well.

If possible, should try to fold over the edge. This will give the smoothest, non cutting skin edge.

  • 2
    Thank you! :) OP might also consider "seaming pliers" or "sheet metal clamps". These are designed with wide, flat jaws for bending metal seams flat. Though I don't think they'll get a final edge, the metal jaws should flatten small waves that could be too stiff for a piece of soft pine 2x4 to flatten. I'd actually use them first to get rid of the little ridges, then use the 2x4 to get rid of the bigger waves.
    – FreeMan
    Sep 7, 2021 at 15:16

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