Are you looking for a powerful tool to help you cut through metal with ease?
Look no further than the Sawzall, a reciprocating saw that can tear through bolts, rods, rebar, pipes, and more.
With its versatile blade orientation and adjustable shoe, the Sawzall is a go-to tool for demolition and remodeling projects.
But how do you use it effectively and safely?
In this article, we’ll guide you through the basics of using a Sawzall to cut metal, including tips on blade selection, cutting techniques, and safety precautions.
So grab your Sawzall and let’s get cutting!
How To Use A Sawzall To Cut Metal
First things first, make sure you have the correct blade for the job. Metal cutting blades are specifically designed for cutting through metal and come in a variety of sizes and tooth configurations. Choose a blade that is appropriate for the thickness and type of metal you will be cutting.
Next, adjust the shoe of your Sawzall to control the depth of your cut. The shoe acts as a guide and can be adjusted up or down to limit the amount of blade that is exposed. This will help prevent the blade from binding or breaking, and also extend the life of your blade.
When you’re ready to start cutting, hold the Sawzall firmly with both hands and position the blade at a 90-degree angle to the metal surface. Start the saw and slowly guide the blade into the metal, using a back-and-forth motion to cut through it.
If you need to make a curved cut, use a smaller blade with finer teeth and make small, controlled movements. For flush cuts, bend the blade slightly so that it rides flat against the surface and use the tip of the blade to make your cut.
It’s important to keep in mind that reciprocating saws are best suited for rough cutting and demolition work. They are not designed for making precise, clean cuts like a handsaw or jigsaw. If you need a more precise cut, consider using a different tool.
Understanding The Sawzall And Its Components
The Sawzall is a type of reciprocating saw that is commonly used for cutting through a variety of materials, including metal. It consists of several components that work together to make the cutting process easier and more efficient.
One of the most important components of the Sawzall is the blade. As mentioned earlier, it’s important to choose the right blade for the job. Metal cutting blades are specifically designed for cutting through metal and come in a variety of sizes and tooth configurations. It’s also important to ensure that the blade is securely fastened to the saw before use.
Another important component of the Sawzall is the shoe, which acts as a guide for the blade. The shoe can be adjusted up or down to control the depth of your cut, which helps prevent the blade from binding or breaking. It’s important to adjust the shoe before starting your cut to ensure that you have enough clearance for the blade.
The motor is another key component of the Sawzall. It provides power to the blade, allowing it to cut through metal quickly and efficiently. When choosing a Sawzall, it’s important to consider the power of the motor, as well as its speed and stroke length.
Finally, the handle is an important component of the Sawzall that helps you maintain control while cutting. Most Sawzalls have a handle on either side of the saw, which allows you to grip it firmly with both hands. This helps you maintain control while cutting through metal, which can be difficult and dangerous if not done properly.
Choosing The Right Blade For Cutting Metal
Choosing the right blade for cutting metal is crucial to achieving a clean and efficient cut. There are a variety of metal cutting blades available, each designed for specific types of metal and thicknesses.
For thinner metals such as sheet metal, use a bi-metal blade with 18-24 teeth per inch (TPI). For thicker metals like steel pipe or angle irons, use a bi-metal blade with 14-18 TPI. When cutting aluminum, an 8-10 TPI blade is best.
It’s also important to consider whether the blade is ferrous or non-ferrous. Ferrous blades are ideal for cutting metals that contain iron, such as stainless steel or cast iron. Non-ferrous blades are better for softer metals like aluminum or copper. For the best results, use a diamond blade that’s rated to cut the type of metal you are working with. Diamond blades have superior strength and hardness, making them perfect for making neater cuts and lasting longer.
When using a circular saw, it’s important to choose the correct blade for the material you are cutting. A metal-cutting blade should not be used in the same saw as the type used for wood because wood-cutting circular saws have an open motor housing that can’t handle metal chips. Use a worm drive blade if possible, as it provides extra torque. Carbide-tipped abrasive cutoff wheels are ideal for non-ferrous metals like brass, aluminum, copper or lead because they last up to 10 times longer than regular steel ones.
When using a hacksaw, choose the correct TPI (teeth per inch) for the type of metal you will be cutting. The larger the blade, the lower the number of teeth per inch. For heavy-duty cutting jobs like steel reinforcing rods or pipes, use an 18-teeth per inch blade. For medium-duty cutting jobs like thin wall electrical conduit, use a 24-teeth per inch blade. For light metals like aluminum, use a 32-teeth per inch blade.
Preparing The Metal For Cutting
Before you start cutting, it’s important to properly prepare your metal. This will not only ensure a clean and precise cut, but also help prevent any accidents or injuries.
First, determine the type of metal you will be cutting. Different metals require different blades for optimal cutting results. For example, ferrous blades are ideal for cutting metals that contain iron, such as stainless steel or cast iron. Non-ferrous blades, on the other hand, are better suited for softer metals like aluminum or copper.
Once you have the appropriate blade, clean the surface of the metal to remove any debris or coatings that could interfere with your cut. You can use an angle grinder with a wire wheel or brush attachment to clean the surface and create a smooth surface for cutting.
Next, mark your cut line using a straight edge or marker. This will help guide your saw and ensure a straight cut.
Finally, adjust the shoe of your Sawzall to control the depth of your cut. This will help prevent the blade from binding or breaking and ensure a clean cut. Start the saw and slowly guide the blade into the metal, using a back-and-forth motion to cut through it.
Basic Cutting Techniques For Metal With A Sawzall
When cutting metal with a Sawzall, it’s important to use the correct technique to ensure a clean and efficient cut. Here are some basic cutting techniques to keep in mind:
1. Use a metal cutting blade: Metal cutting blades are specifically designed for cutting through metal and come in a variety of sizes and tooth configurations. Choose a blade that is appropriate for the thickness and type of metal you will be cutting.
2. Adjust the shoe: The shoe of your Sawzall acts as a guide and can be adjusted up or down to limit the amount of blade that is exposed. This will help prevent the blade from binding or breaking, and also extend the life of your blade.
3. Use a back-and-forth motion: When cutting through metal, use a back-and-forth motion to guide the blade through the material. This will help prevent the blade from getting stuck or breaking.
4. Start slowly: When starting your cut, begin with a slower speed until you get a feel for how the Sawzall handles on the metal. Once you have established control, you can increase your speed to make your cut more efficiently.
5. Use small, controlled movements for curved cuts: If you need to make a curved cut, use a smaller blade with finer teeth and make small, controlled movements to guide the blade through the metal.
6. Bend the blade for flush cuts: For flush cuts, bend the blade slightly so that it rides flat against the surface and use the tip of the blade to make your cut.
By following these basic cutting techniques, you can ensure that you get clean and efficient cuts when using a Sawzall to cut through metal.
Advanced Cutting Techniques For Metal With A Sawzall
If you’re looking to take your metal cutting game to the next level with a Sawzall, there are a few advanced techniques you can try out. One technique is to change the angle of your cut by lowering or raising your trigger hand in relation to the workpiece. This can speed up the cutting time and give you more control over the direction of your cut.
Another technique is to insert the blade into the saw in a way that best suits the application. For example, if you’re cutting through a material that is flush to the floor, it can be useful to insert the blade with the teeth facing upwards and then flip the tool upside-down so that the handle does not get in the way.
If you’re cutting thinner materials, using a smaller blade can help limit “waggle” during use. Generally, the blade should only be a couple of inches longer than the depth of cut required. On the other hand, if you’re flush cutting, choosing a longer blade can be useful as it will bend to enable a greater proportion of the cutting edge to ride flat.
Setting your Sawzall to a slower speed than for wood cutting will extend the blade life and provide more control and precision. Adjusting the shoe to ensure it is set at the most appropriate point on the blade will also help guide the blade until it gains purchase in the metal.
Finally, if you find that your Sawzall blade has become buckled, it can be easily straightened by placing it on a flat surface, putting a flat piece of wood over the damaged area, and hitting the wood a few times with a hammer. Just be careful not to damage the teeth. And don’t forget that blades that have become too worn to cut metal can often be repurposed for use cutting plastics.
By using these advanced techniques and taking care of your Sawzall blade, you’ll be able to tackle even tougher metal cutting jobs with ease.
Safety Precautions When Using A Sawzall To Cut Metal
When using a Sawzall to cut metal, it is important to take proper safety precautions to avoid injury. The following tips will help you operate your Sawzall safely:
1. Wear appropriate personal protective equipment (PPE). Always wear impact-resistant safety goggles to protect your eyes from flying debris. Sturdy gloves are also advised to protect against cuts. A dust mask and ear covers are also recommended.
2. Select the correct blade for the metal being cut. The recommended blades for thin metal are those with 20-24 teeth per inch, for a medium thickness of metal between 10-18 teeth per inch, and for very thick metal a blade with around 8 teeth per inch is recommended. A Bi-metal saw blade set that contains a selection of blades suitable for a range of commonly performed projects is a worthwhile investment.
3. Set the saw to a slower speed than for wood cutting, as this will extend the blade life and provide more control and precision.
4. Maintain your balance and use two hands when operating your Sawzall. Keep the grips clean and free of dirt and dust. Inspect the blades prior to using the saw to make sure they are sharp enough for the required job.
5. Ensure proper blade settings. Never set a blade to go further than 0.32-0.64 cm deeper than the material that you cut.
6. Turn off and unplug the tool when changing or cleaning reciprocating saw blades.
7. Avoid pulling the blade out of your cut while the blade is still moving, as this can cause kickback and potentially injure you.
8. Give the blade time to cool down before trying to change it, as it can generate a lot of heat during use.
By following these safety precautions, you can use your Sawzall to cut metal safely and effectively. Remember, always prioritize safety when working with power tools.