How to Cut Metal Pipes, Bolts, Sheet Metal, and More

Despite the many uses for metal, it can be a difficult material to work with, so most DIYers avoid jobs that involve metalwork. However, almost every type of metal can be cut. It's just important to select the correct blade or grinding disc.

Metal is split broadly into ferrous and nonferrous varieties. Metals containing iron are considered ferrous metals, which tend to be more difficult to cut, such as steel bolts or steel rebar. Metals that do not contain iron, like aluminum or copper, are nonferrous metals, which are generally softer and easier to work with.

Use this guide to discover how to cut metal in 15 different ways.

Safety Considerations

Airborne metal shavings and sparks are common when cutting metal, so you should wear fire-resistant clothing, shaded safety glasses, gloves, closed-toe shoes, and a mask. Avoid wearing loose clothing or jewelry while you work, and if you have longer hair, tie it up so it's out of the way.

Check the area around where you are working to ensure that there isn't anything flammable. Open a few windows and doors to ventilate the space, but if that isn't possible, then wear a respirator while you work and set up a few fans to help improve airflow through the area. If you use a plasma torch or an oxy-acetylene torch, then you must wear welding gloves, shaded eye protection, a protective jacker or welders apron, and non-flammable clothing.

How to Cut Metal With a Hacksaw

One of the original tools used for cutting through metal is the hacksaw. This manual saw comes in both standard and mini sizes, allowing you to select the saw that best fits the space. By pushing the blade forward across metal pipes, metal bolts, or sections of sheet metal, the hacksaw teeth gradually cut through the material.

However, this method takes more time and physical effort than most other ways to cut through metal, so it's generally only used for smaller cuts or when a power tool isn't available.

Compound Snips

Compound snips have a few different names—they can also be referred to as tin snips or metal shears. This tool is essentially a set of heavy-duty scissors that are designed for cutting through soft nonferrous metals, like aluminum and copper, as well as thin sheet metal.

Simply line up the blades, like a set of scissors, then squeeze the handles together to slice through the metal. Compound snips are easy to use for small cuts, but aren't the best option for larger jobs.

Utility Knife

A utility knife isn't the best way to cut through metal since it can really only be used for very thin pieces of metal, but if it's used properly, it can be a quick way to score and snap pieces of light-gauge metal, like aluminum siding.

Use the utility knife and a straight edge to cut a deep furrow in the light-gauge metal. Clamp or hold one side of the metal, then apply pressure to the metal on the other side of the cut. If done correctly, the metal should break off cleanly at the furrow made by the utility knife.

Bolt Cutters

As the name implies, bolt cutters are designed for cutting through metal bolts. They can also be used for cutting screws, nails, chains, rebar, padlocks, wire mesh, and more. Bolt cutters have long handles and short blades, allowing you to use the extra leverage provided by the long handles to apply more force to the cutting blades.

Position the blades on either side of the target material, then close the handles to cut through the metal. Keep in mind that bolt cutters are manual tools, so the force to cut through the metal needs to come from the user. Due to this limitation, bolt cutters are not often used for long or overly difficult metal cutting projects.

Circular Saw

A circular saw with the right cutting blade can cut through sheet metal, rebar, and other metal materials without much difficulty. However, the increased cutting power and cutting speed means that the metal will get hotter during the cutting process. The saw will also create sparks and may sends small bits of metal, similar to sawdust, into the air while you work, so it's important to wear proper protective equipment.

Simply line up the saw with the target material, press the trigger to start the cutting blade, then move the saw into the material, applying pressure to keep the circular saw moving forward at an even pace until the cut is completed. This method of cutting metal can be used in most cases as long as there is space to properly maneuver the saw.

Oscillating Tool

Similar to a circular saw, an oscillating tool can be used to cut most metals if it has the right blade. However, oscillating tools are not suitable for large sheets of metal or big cutting jobs, instead these tools are used when access is tight or you need to make a flush cut. Attach the metal-cutting blade, then line up the blade with the target material, like a plumbing pipe, bolt, nail, or a screw. Start the oscillating blade, then move it into and through the target material at a constant pace until the cut is complete.

Reciprocating Saw

When an oscillating tool is too small, but a circular saw is too big, you can use a reciprocating saw with a metal-cutting blade to cut through soft or light-gauge metal, nails, screws, bolts, or even pipes. A reciprocating saw moves back and forth, similar to a hacksaw, to it's important to keep the target material still while cutting.

Use a bench clamp for loose material or have a second person hold pipes, metal studs, and fixed material. Align the cutting blade, then start the saw and cut through the target metal. However, this method isn't the best option since the sawing motion can be difficult to control for inexperienced DIYers.

Miter Saw

A miter saw equipped with a metal-cutting blade is an excellent option for making accurate, repeatable cuts through rods, pipes, tubes, and other relatively thin metal materials. The saw can swing from left to right and the angle of the blade can be adjusted to make mitered cuts in the material.

After setting the desired angle, just squeeze the trigger to start the blade, then lower the blade down until it cuts completely through the material. The drawback with this saw is that it's stationary, so it can be difficult to cut larger sheets of metal.

Hole Saw

There are many building projects that require circular holes, which is what the hole saw is designed to accomplish. Select a metal cutting saw blade that can handle the target metal. Measure and mark the intended hole, then use the saw to cut through the metal.

A hole saw has a circular blade that rotates rapidly to cut through the metal. Press the trigger on the saw to start the blade, then lower it to the metal and apply force to cut through the material.

Nibbler

A nibbler is used to make long cuts in thin-gauge metal without bending, chipping, or otherwise distorting the metal object. It's essentially a powered upgrade from a set of compound snips, though it has more of a pistol-shape.

Align the nibbler bit with the target metal material, then squeeze the trigger to active the device. Apply force to drive the nibbler through the metal, keeping a constant pace to avoid putting too much pressure on the material. Continue until the nibbler has completed the cut, then release the trigger.

Bench Shear

There are straight bench shears and throatless bench shears. Straight bench shears are used to make straight cuts, while throatless sheers are used for cutting curves and other complex shapes.

This tool operates similarly to a paper cutter. Simply situate the metal under the blade, then use the lever to pull the blade down and slice through the metal. The thicker the metal, the more difficult it is to cut.

Horizontal Band Saw

A band saw with a metal-cutting blade can be used to cut through both thick and thin pieces of metal. Just turn the saw on, then feed the metal into the saw.

The cutting blade will handle the rest of the work, though it's important to note that band saw blades dull quickly when cutting metal, so make sure to replace the blade frequently for accurate cuts.

Cold Saw

While a miter saw or chop saw can cut through metal, it tends to rapid heat the metal in the process, which can cause burning or deformation. A cold saw cuts similar to a miter saw, but it uses a cooling feature to keep the metal cool while you work. This reduces the friction and creates a cleaner, more precise cut.

However, a cold saw is an expensive piece of equipment, so it may not be worth it for one-time or infrequent metal-cutting jobs.

Plasma Torch

For metal that is 0.25 inches or thinner, a plasma torch can be an effective cutting tool. Wear proper protective gear for using a high-powered torch and clear out any flammable materials.

Turn on the tank and light the torch to produce a thin, high-temperature flame. Use the flame to cut through the target metal, then turn the tank off and allow the metal to cool. This metal cutting method is quick and efficient, though it can be dangerous for inexperienced individuals.

Oxy-Acetylene Torch

Oxy-acetylene torches should only be used by experienced individuals due to the potential risks with using this tool. By creating a high-temperature flame, the oxy-acetylene torch can cut through steel up to 48 inches in thickness.

After donning the appropriate protective equipment and ensuring the area is safe to work in, turn the tank on. Set the pressure to about five PSI, then light the nozzle of the torch. Use the flame to cut through the target metal, then turn the tank off and allow the metal to cool.

Frequently Asked Questions

What is the best thing to cut metal with?

The best tool to cut metal depends on the thickness and hardness of the metal. Angle grinders or circular saws with an abrasive metal cutting disk are a great option for small cuts through thin steel. When dealing with thick metal, a bench shear or a cold saw are the best options, though these tools tend to have a high price tag, so they may not be worth the investment for a one-time project.

Can you cut metal without a saw?

There are a variety of tools you can use to cut metal without a saw, including tin snips, a nibbler, an angle grinder, a bench shear, a plasma torch, and an oxy-acetylene torch.

How do you cut steel quickly?

The method to cut steel quickly changes depending on the thickness and hardness of the steel. You can cut through thin sheets of steel easily with tin snips, a hack saw, a nibbler, a reciprocating saw, or an angle grinder. For thick pieces of steel, use a bench shear, circular saw, chop saw, or a cold saw. If you have the skill and experience, you can also cut thicker pieces of steel with a plasma torch or an oxy-acetylene torch.

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Read the original article on The Spruce.