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This all depends on the tools you have on hand and whether you’re trying to cut a straight line or shapes. 

The best tool to use for straight lines is either a circular saw or table saw. When cutting shapes, a jigsaw will be the easiest and most precise tool to use. 

The cost to weld aluminum averages about $14 to $22 per pound. The type of metal factors into the overall cost of any welding project due to the cost of the materials and the expertise required to work with it. Some of the most common metals used by welders include:

• Magnesium alloy: $7–$16 per pound

• Low-carbon steel: $11–$12 per pound

• Stainless steel: $13–$15 per pound

• Copper/brass: $24–$29 per pound

• Cast iron: $38–$79 per pound

• Titanium: $60–$85 per pound

Cutting rectangular ductwork requires careful measurements and the right technique. Use a measuring tape and pencil to mark the cutting lines accurately. Tin snips are excellent for straight cuts on smaller ducts. For more extensive or thicker rectangular ducts, a reciprocating saw with a metal-cutting blade is effective. 

Ensure the duct is well-supported and secure while cutting to prevent wobbling and maintain precision. After cutting, use a metal file to smooth any sharp edges, ensuring safety during installation. 

Cutting round ductwork requires precision and the right tools. A duct cutter, specifically designed for circular ducts, is ideal. First, mark the cutting line on the duct using a measuring tape and pencil. Then, position the duct cutter's blade on the marked line. Apply steady pressure, rotating the cutter around the duct. The sharp blade creates a clean, precise cut. Alternatively, a reciprocating saw with a metal-cutting blade can be used for larger round ducts. Ensure the duct is securely held in place while making the cut to prevent slips and maintain accuracy.