Originally Posted By: SideDriftin'
Doing a diamond plate floor is just like doing a wood floor. Trace out old floor board on the back (smooth side) of diamond plate, grab a Skil saw with a sharp carbide blade and cut away. You will have to cut at about half the speed of wood but it cuts easy. Wear some kind of eye protection as aluminum shavings suck in the eyes (don't ask how I know this). grin

It's similar.
Clamp your work down...aluminum will accumulate on the blade and the work will want to "buck" occasionally.
To minimize that effect, use industrial stick wax.
Cheap, works well for tapping, too.
Comes in a tube (caulking tube size), just run your blade into it to coat the blade.

I would cut a touch big and finish with a belt sander where the cut is visible, such as in the front area.

Edit:
Yes, eye pro is a must. A face shield would be best.
Aluminum chips fly in a very nasty way.
They hurt when they hit, too.

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