Are you wondering if a Sawzall can cut through metal?
The short answer is yes, it can. But the real question is, how well can it cut through metal? And what kind of blade do you need to use?
Reciprocating saws, also known as Sawzalls, are incredibly versatile tools that can cut through a wide range of materials, including wood, nails, fiberglass, branches, plaster, masonry, and various metals.
However, the key to cutting metal with a Sawzall is using the right blade. In this article, we’ll explore the different types of blades available and provide tips on how to choose the best one for your metal cutting needs.
So let’s dive in and find out if a Sawzall is the right tool for your next metal cutting project.
Can A Sawzall Cut Through Metal
As mentioned earlier, a Sawzall can cut through metal, but the type of metal and the blade you use will affect how well it cuts. In general, lighter gauge metals like aluminum or copper are easier to cut with a reciprocating saw than thicker steel or cast iron.
When it comes to choosing the right blade for cutting metal, a carbide-tipped blade designed specifically for metal cutting will work best. These blades have teeth that are specially designed to cut through metal and can withstand the heat generated by the friction of cutting through metal.
It’s important to note that using the wrong blade can result in a poor cut or even damage to your Sawzall. For example, using a wood cutting blade on metal can cause the teeth to dull quickly and potentially break off, which can be dangerous.
Understanding The Basics Of Sawzall Blades
Reciprocating saws like the Sawzall are incredibly versatile tools, and one of the reasons for this is the wide range of blades available for cutting through various materials. When it comes to choosing the right sawzall blade for metal cutting, there are several factors to consider.
One of the most important factors is teeth-per-inch (TPI). Blades with a higher TPI are generally better suited for cutting metal. For cutting thinner metals like sheet metal, a blade with 18-24 TPI is recommended. For thicker metals like steel pipe or angle irons, a blade with 14-18 TPI is best. For aluminum, an 8-10 TPI blade will work well.
Blade material is another important consideration. Bi-metal blades are a popular choice for cutting metal as they are durable and can withstand the heat generated by cutting through metal. Carbide-tipped blades are even more durable and are recommended for cutting harder metals like cast iron or high-strength alloys.
Blade shape, tooth shape, kerf-width, gullet, and tooth pattern can also be selected for specific cut types. However, it’s important to note that using the right blade for the material you’re cutting is more important than selecting a specific blade shape or pattern.
Types Of Sawzall Blades For Cutting Metal
There are several types of Sawzall blades for cutting metal, each with its own unique features and benefits. The right choice will depend on the type of metal you are cutting and its thickness. Here are some of the most common types:
1. Bi-metal blades: These blades are made from two types of metal, typically high-speed steel and high-carbon steel. They are durable and flexible, making them a good choice for cutting a variety of metals. Bi-metal blades come in a range of TPI (teeth per inch) to accommodate different thicknesses of metal.
2. Carbide-tipped blades: These blades are designed to cut through harder, denser metals like cast iron, alloys, and high-strength steel. They are extremely hard, heat-resistant, and impact-resistant, making them ideal for tough jobs like auto dismantling or fire and rescue work. Carbide-tipped blades typically have a lower TPI than bi-metal blades.
3. Diamond-grit blades: These blades have no teeth but instead have a blade edge coated with coarse diamond grit. They are particularly good at cutting through extremely hard materials like cast iron or concrete.
4. Torch blades: These blades are designed for thick metal cutting applications and offer a good balance of performance and value. They optimize cutting performance for black pipe, cast iron, angle iron, and even stainless steel without being quite as expensive as blades dedicated to those extreme cutting applications.
5. High carbon steel (HCS) blades: These blades are the most common type of Sawzall blade and are relatively inexpensive, flexible, and moderately durable. They can cut wood, plastic, and many composites as well as thin gauge metals.
When choosing a Sawzall blade for cutting metal, it’s important to consider the type of metal you will be cutting, its thickness, and the specific features of each blade type. Using the right blade will ensure a clean cut and prolong the life of your Sawzall.
Factors To Consider When Choosing A Sawzall Blade For Metal Cutting
When choosing a Sawzall blade for metal cutting, there are several factors to consider:
1. Teeth Per Inch (TPI): The TPI of the blade is a crucial factor in determining its reliability. Blades with a higher TPI are better suited for cutting thinner metals like sheet metal, while blades with a lower TPI are better suited for thicker metals like steel pipe or tubing.
2. Blade Material: The material of the blade is also an important consideration. Bi-metal or carbide-tipped blades are best for cutting metal. Bi-metal blades are made from high-carbon steel and hot-work steel teeth, while carbide-tipped blades have a tungsten carbide or titanium carbide tip at the end of each tooth.
3. Blade Length: The length of the blade should be chosen based on the thickness of the metal being cut. Longer blades are better suited for thicker metals, while shorter blades are better for thinner metals.
4. Blade Width: The width of the blade should also be chosen based on the thickness of the metal being cut. Wider blades are better suited for thicker metals, while narrower blades are better for thinner metals.
5. Blade Thickness: The thickness of the blade should be chosen based on the type of metal being cut. Thicker blades are better suited for cutting harder metals like cast iron or stainless steel.
6. Blade Shape: The shape of the blade can also impact its performance. For example, a straight blade is better suited for cutting through flat surfaces, while a curved blade is better suited for cutting through pipes or tubing.
7. Gullet: The gullet is the space between the teeth on the blade. A larger gullet can help prevent clogging when cutting through thicker metals.
By considering these factors, you can choose the right Sawzall blade for your specific metal cutting needs and ensure a clean and efficient cut every time.
How To Properly Use A Sawzall For Cutting Metal
Before you start cutting metal with your Sawzall, make sure you have the right blade for the job. As mentioned earlier, a carbide-tipped blade designed specifically for metal cutting will work best. These blades have teeth that are specially designed to cut through metal and can withstand the heat generated by the friction of cutting through metal.
Once you have the right blade, it’s important to wear proper safety gear, including goggles or glasses to protect your eyes from flying debris. You should also wear ear protection as reciprocating saws can be quite loud.
When cutting metal, it’s important to use a slow and steady motion. Don’t force the blade through the metal, as this can cause it to overheat and potentially break. Instead, let the blade do the work and apply gentle pressure.
It’s also important to pay attention to the orbital cutting feature on your Sawzall. For cutting through metal, you should turn this feature off completely. If you don’t, the blade will bounce off the metal surface, slowing down the cut and potentially causing damage.
Finally, be aware of your surroundings when cutting metal with a Sawzall. Make sure there are no flammable materials nearby and that no one is standing in the path of the blade. With proper technique and safety precautions, a Sawzall can be a great tool for cutting through metal.
Safety Tips For Using A Sawzall To Cut Metal
When using a Sawzall to cut metal, it’s important to take proper safety precautions to avoid injury. Here are some tips to keep in mind:
1. Wear personal protective equipment: Always wear the proper gloves, dust mask, ear covers, and safety goggles when using a Sawzall to cut metal. Slip-resistant footwear is also recommended.
2. Choose the right blade: As mentioned earlier, using the right blade is crucial for cutting metal effectively and safely. A carbide-tipped blade designed specifically for metal cutting will work best.
3. Maintain electrical safety: Never use an electric Sawzall during wet conditions. Use the saw with Ground Fault Circuit Interrupter (GFCI) protected outlets or extension cords. Check the tool cord for damage prior to use, and if a problem is detected, do not use it.
4. Keep the blade cool: Blades heat up quickly when cutting through metal, which can cause them to dull faster. To prevent this, rub on blade lubricant between cuts to keep the blades cooler and the teeth free of clogs from metal chips.
5. Use proper technique: Always maintain your balance and use two hands when operating your Sawzall. Keep the grips clean and free of dirt and dust. Never set a blade to go further than 0.32-0.64 cm deeper than the material that you cut.
6. Be aware of kickback: One of the main hazards of reciprocating saws is their potential for kickback. That can happen if you make the mistake of pulling the blade out of your cut while the blade’s still moving. The tip of the blade smacks into the material you’re cutting, and the whole saw, including the moving blade, kick back toward you.
7. Let the blade cool down before replacing it: A saw blade can generate a lot of heat, so give it some time to cool down before trying to change it.
By following these safety tips, you can avoid injuring yourself while using a Sawzall to cut metal effectively and safely.
Common Mistakes To Avoid When Cutting Metal With A Sawzall
While a Sawzall can be a useful tool for cutting metal, there are some common mistakes that should be avoided to ensure safety and optimal results.
One of the biggest mistakes is using the wrong blade for the type of metal being cut. As mentioned earlier, carbide-tipped blades are ideal for cutting metal, but it’s important to select a blade that’s rated to cut the specific type of metal you’re working with. Using the wrong blade can result in poor cuts, damage to the tool, or even injury.
Another mistake is not wearing appropriate safety gear. Eye and ear protection should always be worn when using a reciprocating saw to protect against flying chips and offcuts. Sturdy gloves are also recommended to protect against cuts.
Using too much force or trying to make the tool work faster than it was designed for is another common mistake. It’s important to let the tool do the work and guide it gently or with only moderate force along the material being cut. Trying to force the tool to cut faster or harder than it was designed for can result in poor cuts, damage to the tool, or injury.
Lastly, not using the proper nibbler or shear for the gauge of material being cut is another common mistake. Nibblers are designed for cutting both flat and corrugated sheet metal, while shears are only used for flat sheets. Using the wrong tool can result in poor cuts or damage to both the tool and material being cut.
By avoiding these common mistakes and selecting the right blade and safety gear, a Sawzall can be an effective tool for cutting through metal.