10 Easy Ways to Cut Metal Fast

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Cut Metal with Your Circular Saw

It may not be an obvious choice, but fitted with the right blade, a circular saw is a great metal-cutting tool. In our test, it cut through rebar like a hot knife through butter. You can cut mild steel up to about 3/8 in. thick using a ferrous-metal-cutting blade. Be careful, though! Hot metal chips will fly everywhere. Put on your safety gear, keep bystanders away, and cover anything you don’t want coated with metal chips. There are two types: inexpensive steel-tooth blades and carbide-tooth blades. Carbide-tooth blades are more expensive but will last longer.

It doesn’t matter if you’re a long-time DIYer or just starting out on some projects, there are some tools of the trade that are crucial in getting jobs done.

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Cut Aluminum with Your Miter Saw

Making accurate cuts on aluminum rods, tubes and angles is easy with a miter saw and a blade designed to cut nonferrous metal (check the label). If the motor housing on your saw is open and could collect metal chips, tape a piece of cloth over the openings to protect the motor windings and bearings while you cut the aluminum. (Remember to remove it when the saw goes back into regular service or the motor will overheat.) Trapping the aluminum with a wood backer as shown reduces the danger of flying metal shards and makes it easier to hold the metal in place for cutting. This tip is especially important when you‘re cutting thin-walled pieces. Without the backing board, the blade will often catch on the metal and distort it and make it unusable.

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Family Handyman

Tips for Cutting Metal Safely

Cutting or grinding metal sends tiny chips or shards of metal everywhere. And they can be hot and sharp. To avoid eye injuries, cuts, burns and other injuries from cutting metal, follow these rules:

Read and observe safety precautions printed on metal-cutting discs and blades.
Wear safety glasses, a face shield and hearing protection.
Cover all exposed skin with gloves, long-sleeve shirt and pants.
Allow freshly cut metal to cool before touching it.
Wear gloves when handling metal that could have sharp edges.
Securely clamp metal before cutting it.
Never allow anyone near you while you’re cutting metal unless they’re wearing hearing and eye protection.