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black exterior aluminum railings for a front porch

HOW TO CUT ALUMINUM RAILING AND ALUMINUM DECK RAILING: A STEP-BY-STEP GUIDE


The first answer to the question, “How do you cut aluminum railing?” is simple: Very carefully! Aluminum is a fantastic material for railings because it’s lightweight, strong, and easy to work with—but cutting it the right way takes some planning and know-how.


Now, here’s the thing: not all aluminum railing systems need to be cut. When you work with a custom aluminum railing system like the ones we design at Terrace Aluminum Railings, everything is measured and built to fit your space perfectly—no extra cutting required. But, if you’re using an off-the-shelf aluminum deck railing kit from stores like Home Depot or Lowe’s, you’ll often need to cut the pieces to fit your specific deck, front porch, or stairs.

The good news? Cutting aluminum railing—or even a deck with aluminum railing—isn’t hard, but it does require the right tools, the right blade, and a good understanding of safety measures. Whether you’re tackling a small adjustment for a front porch railing or cutting sections for a full aluminum deck railing system, this guide will walk you through the process. We’ll cover the tools you’ll need, the best type of blade, and essential safety tips to make sure the job gets done right. Plus, we’ll share common mistakes to avoid so your cuts are clean, precise, and professional-looking.

By the end of this blog, you’ll feel confident cutting aluminum railing and aluminum deck railing for your next project. And if you decide cutting isn’t your thing, don’t worry—our team at Terrace Aluminum Railings is always here to help. Let’s get started!


The Best Tools for Cutting Aluminum Railing, Deck Railing, and Front Porch Railing:

When it comes to cutting aluminum railing for a deck, front porch, or staircase, the best tool for a clean, precise finish is a mitre saw with a non-ferrous blade. At Terrace Aluminum Railings, this is our tool of choice because it delivers professional results every time. Here’s what you need to know about the tools, blades, and alternatives for cutting aluminum railings.


Our Go-To Tool: The Mitre Saw

For the cleanest cut, we recommend using a 10-inch mitre saw fitted with a blade designed for non-ferrous metals. Why a 10-inch saw? It’s just the right size—not too big, not too small. The blade we prefer is an 80-tooth blade, perfect for cutting medium metal. While some people use a 96-tooth blade, we find the 80-tooth provides the perfect balance of smoothness and efficiency.

Our custom aluminum railing systems, whether for a deck or front porch, require a flush finish against the post. The precision of a mitre saw is absolutely essential to achieve that professional, seamless look.

For Store-Bought Railing Systems

If you’ve purchased an aluminum deck railing kit or front porch railing system from Home Depot or Lowe’s, you may have more flexibility with your cuts. Many of these systems have rail ends hidden inside sleeves, often with up to 1.5 inches of play. This means you don’t always need a perfectly square cut.

Here are some alternative tools you can use:

  1. Sawzall with a Metal Blade
    • A solid second choice for cutting aluminum railings, especially for deck projects or adjustments on a front porch railing. Use a high-quality metal blade for cleaner results.
  2. Grinder with a Metal Cut-Off Blade
  3. Cut-Off Tool
    • Handy for small adjustments but less accurate for longer cuts.

While these tools are helpful, they may leave rough edges or uneven finishes, especially on exposed sections of the railing. For visible parts of your deck railing or front porch railing, stick to the mitre saw for the best results.

No matter which tool you use, safety is non-negotiable. Cutting aluminum produces tiny metal shards that can fly at high speeds. If you’re using a grinder, these shards are also extremely hot. Follow these safety tips to protect yourself:

  • Always wear safety glasses to shield your eyes from debris.
  • Don’t rely on the “squint method”—your eyes deserve better!
  • Consider cut-resistant gloves for added protection when handling freshly cut aluminum pieces.

Pro Tip

If you’re cutting railings for a full deck with aluminum railing or a front porch, measure twice (or even three times!) before making any cuts. Even a slight misalignment can stand out, especially on visible sections of your project.


Mistakes to Avoid When Cutting Aluminum Railing and Aluminum Deck Railing


Cutting aluminum railing or aluminum deck railing may seem straightforward, but a few common mistakes can lead to uneven cuts, damaged materials, or even safety issues. Here are some key mistakes to avoid so you can get a clean, professional result every time.

1. Cutting Too Fast with the Mitre Saw

One of the biggest mistakes is rushing the cut. If you bring the blade down too quickly, the saw can bend or bind, potentially damaging both the mitre saw and your aluminum track or handrail. Instead, take your time and let the blade do the work. A slow, steady motion ensures a smooth, clean cut and prevents unnecessary wear on your tools.

2. Cutting on Different Sides for the Top and Bottom Rail

When cutting both the top and bottom rails of your aluminum railing system, consistency is key. Always ensure you’re cutting from the same side of the railing for both pieces. Cutting from different sides can result in misaligned rails, which won’t fit properly during installation. This is especially important for custom projects where precision is critical.

3. Incorrect Picket Spacing

Proper picket spacing is essential for meeting building codes and maintaining a polished look. In Toronto and the GTA, the building code requires that the space between pickets be less than 4 inches (100mm). To achieve this:

  • Start by finding the center of one picket and use it as your halfway point.
  • Measure outward from this point to ensure the end pickets on both sides are equally spaced.
  • The center pickets should have a standard spacing of approximately 3.75 inches to stay within code.

Uneven spacing can make your railing look unbalanced and may result in compliance issues, so double-check your measurements before cutting.

4. Failing to Keep the Railing Level During the Cut

Another common mistake is not keeping the railing level with the saw. If the railing isn’t perfectly level, the cut may end up with a bevel, leaving the edge uneven and unsuitable for a flush fit. To avoid this:

Check the alignment before and during the cut to ensure accuracy.

Use a saw stand or other support to keep the railing steady and level with the cutting surface.



Pro Tips for a Flawless Finish

  • Double-Check Everything: Measurements, alignment, and saw settings should all be confirmed before making the cut.
  • Practice on Scrap Pieces: If you’re new to cutting aluminum, practice on a spare piece to get a feel for the process and avoid mistakes on your actual railing.
  • Take Your Time: Precision takes patience. Rushing through cuts is one of the fastest ways to make costly mistakes.

By avoiding these common pitfalls, you’ll save time, money, and frustration while ensuring your aluminum deck railing or front porch railing looks perfect and meets all safety requirements.


Deciding whether to cut and install your aluminum railing or aluminum deck railing yourself depends on your comfort level, tools, and the complexity of the project. While DIY can be a rewarding experience, there are times when hiring a professional is the best choice.

When DIY Makes Sense

  • Simple Projects: If you’re working on a straightforward railing system for a small deck or front porch, and you have the necessary tools (like a mitre saw), DIY is a great option.
  • Basic Cutting Needs: Kits from stores like Home Depot or Lowe’s often allow for some flexibility, making them more forgiving for beginners.
  • Budget-Friendly Solutions: If you’re comfortable measuring, cutting, and installing, DIY can save on labor costs while still giving you a polished result.

When to Hire a Professional

  • Custom Railing Systems: For precision work on custom aluminum railing systems, hiring a pro ensures your railings are measured, cut, and installed perfectly.
  • Complex Installations: Projects involving staircases, multiple levels, or unique designs often require advanced tools and experience.
  • Strict Building Codes: In Toronto and the GTA, railing installations must meet specific safety codes, like spacing requirements for pickets. A professional will ensure compliance with all regulations.
  • Time and Expertise: If you’re short on time or not confident in your skills, hiring a professional can save you stress and ensure flawless results.

At Terrace Aluminum Railings, we take care of everything—from precise measurements to the final installation—so you can enjoy a beautiful, safe railing system without lifting a finger.

Closing Thoughts: Your Aluminum Railing Done Right

black exterior aluminum railings for a front porch

Cutting and installing aluminum railing or aluminum deck railing doesn’t have to be overwhelming. With the right tools, a steady approach, and attention to detail, DIYers can achieve fantastic results for their deck, front porch, or stairs. However, when the project requires precision, custom solutions, or professional expertise, calling in the pros is a smart investment.

At Terrace Aluminum Railings, we’ve been perfecting aluminum railing systems for over 25 years. Whether you’re tackling a DIY project and need advice, or you’d prefer to leave it all to the experts, we’re here to help. From high-quality materials to custom designs that fit your space perfectly, we’ll ensure your project exceeds expectations.

Ready to upgrade your outdoor space with a stunning, durable railing system? Contact us today for a consultation or quote, and let’s make your vision a reality!

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