How to best cut a large diameter (~14") circle out of sheet metal?

In reply to Stampie (FS) :

Don't care much about OSHA. 
 

My issue with using a table saw is if the machine has ever been used to cut wood (duh), then there is sawdust one the bottom cabinet. Grinding wheels throw sparks- fire hazard. 
 

Additionally, many of the sparks will fly up. I'll bet you didn't use a guard for this particular operation, because if you had, it would have melted. 
 

There is no reason to attempt this with a table saw when the exact same thing can be accomplished with a skillsaw (without those risks). 
 

Also, 13" dia is a little small to attempt with a 10" blade. It's easier with a 7 1/4" blade (and even easier with a jig saw blade)

In reply to Mr_Asa :

If it has a pilot hole in the center already, then all of the above listed cutting tools (router, jigsaw, skillsaw, bandsaw, etc) could be used accurately with a guide rod bolted through the pilot hole. 
 

Easy Peazey. 

Do you have access to a plasma cutter?

https://www.eastwood.com/eastwood-plasma-cutting-guide.html

Probably not, but maybe you could adapt this sort of idea to a sabre saw.

Waterjet...

In reply to SVreX (Forum Supporter) :

I'd be more worried about the cutting wheel loading up and shattering than all those aluminum sparks. 

In reply to Crackers (Forum Supporter) :

On a table saw?  Yeah, you're probably right.