Cutting out shapes in sheet steel

[Wedg1e]

Plasma cutter

As the question was 'What would you guys use?' then I'm with you; I cut the top out of a fuel tank in under a minute with my plasma... coincidentally it was 1.2mm thick as well

Lacking the plasma I'd be looking at a holesaw and thin slitting disc. Jigsaw wouldn't be my first choice on thin sheet as it only uses a very small area of the blade which would be blunt in no time, probably leaving 60% of the teeth unused... and with the best will in the world, jigsaws wander meaning some cleanup time afterwards if the edge will be seen.

 

[Kent]

Look. At the tools you actually have already
For the ideal we need to see where the hole is, what stage in the process it needs cutting and how big.

 

[series2]

I use a sheet metal shear, it will cut radii down to 40mm.

https://www.westfalia.net/shops/too...campaign=Google Adwords+WWC Produktdaten+UK

 

[bigegg]

Fretsaw?
Or a cold chisel?

But preferably a plasma cutter.

 

[bigegg]

http://www.axminster.co.uk/pegas-metal-cutting-scroll-saw-blades-ax877557
http://www.axminster.co.uk/jet-jss-16a-scroll-saw-101856

Like these

 

[gt6s]

Plasma cutter and if needed repeatable cut plywood templates. TOO EASY ! Next question.

 

[ChrisJ]

how about a hole saw of the diameter your looking to make the radius for, and then use a jigsaw with a metal saw blade in, I have been cutting shapes from 1.6mmcr4 sheet with really good results

 

[Hitch]

Hole saw te corners, and thin cutting disc for the straights, finish off with a file or die grinder.

 

[zx9]

Hole saw te corners, and thin cutting disc for the straights, finish off with a file or die grinder.

I hope he has got them done by now, before today the pervious post was three months ago.
@Noods are you going to show us what you made, and tell us what way you did it?