metal shear

[Edward Weber]

When cutting with a band saw how do you support the work? I'm imagining the thin metal bouncing up and down as the blade passes producing a rough cut, at least that's been my experience sawing thin sheet metal, hence my idea of sandwiching it in plywood for cutting.

I would get a block of wood, cut an appropriate sized slot, insert metal and cross cut. This keeps the metal captured without bouncing. A small sled or miter gauge fixture is all that's needed.