If you’re looking to customize your car’s exhaust system, you may need to cut through the stock exhaust pipe.
While a cutting wheel can do the job, many car enthusiasts prefer using a Sawzall for its speed and control. However, choosing the right blade and technique is crucial to avoid damaging the underbody of your car or cutting something you shouldn’t.
In this article, we’ll guide you through the steps of cutting exhaust pipe with a Sawzall, so you can achieve the perfect custom piping without any mishaps.
So, let’s rev up our engines and get started!
How To Cut Exhaust Pipe With Sawzall
Step 1: Choose the Right Blade
The first step in cutting exhaust pipe with a Sawzall is to choose the right blade. A bi-metal blade is recommended as it can cut through both metal and plastic materials. Make sure the blade is long enough to avoid getting caught on the other side of the exhaust pipe when the saw pulls back.
Step 2: Prepare the Exhaust Pipe
Before you start cutting, prepare the exhaust pipe by marking the cut line with blue painter’s tape. This will help you make a straight perpendicular cut and avoid any mistakes. You can also use a mini-hack saw to make a kerf to start the Sawzall in.
Step 3: Secure the Exhaust Pipe
To ensure stability and accuracy, secure the exhaust pipe with a hose clamp. This will give you a nice even edge to cut against and prevent any slipping or wobbling.
Step 4: Cut the Exhaust Pipe
Now it’s time to start cutting! Turn on your Sawzall and slowly guide it along the marked cut line. Use a steady hand and keep a firm grip on the tool to maintain control.
Remember to take breaks and let the blade cool down if it gets too hot. This will prevent any damage to the blade or your car’s underbody.
Step 5: Clean Up
Once you’ve finished cutting, remove any tape or clamps from the exhaust pipe. Use a file or sandpaper to smooth out any rough edges or burrs left from the cutting process.
Gathering The Necessary Tools And Materials
Before you start cutting your exhaust pipe with a Sawzall, you’ll need to gather the necessary tools and materials. Here’s what you’ll need:
1. Sawzall: A reciprocating saw, also known as a Sawzall, is the primary tool you’ll need for this project. Make sure it’s in good working condition and has a bi-metal blade attached.
2. Bi-metal Blade: Choose a bi-metal blade as it can cut through both metal and plastic materials. Make sure the blade is long enough to avoid getting caught on the other side of the exhaust pipe when the saw pulls back.
3. Blue Painter’s Tape: This will help you mark the cut line and make a straight perpendicular cut.
4. Hose Clamp: Use a hose clamp to secure the exhaust pipe and ensure stability and accuracy during cutting.
5. Mini-Hack Saw: Optional, but useful for making a kerf to start the Sawzall in.
6. File or Sandpaper: Use these to smooth out any rough edges or burrs left from the cutting process.
Make sure to have all of these tools and materials on hand before starting your project to ensure a smooth and successful cutting process.
Choosing The Right Blade For Your Sawzall
Choosing the right blade for your Sawzall is crucial when cutting exhaust pipe. You want to make sure you have a blade that can cut through both metal and plastic materials. A bi-metal blade is recommended for this job as it is durable and versatile.
It’s also important to choose a blade that is long enough to avoid getting caught on the other side of the exhaust pipe when the Sawzall pulls back. This will prevent any damage to the blade or the pipe itself.
Another factor to consider is the number of teeth per inch on the blade. For thin exhaust pipes, a blade with 20-24 teeth per inch is recommended. For thicker pipes, a blade with around 8 teeth per inch is more suitable.
Before starting the cutting process, make sure to inspect the blade for any damage or wear and tear. A damaged blade can cause accidents or damage to the pipe.
By choosing the right blade for your Sawzall, you can ensure a clean and precise cut on your exhaust pipe with minimal effort and time.
Preparing The Exhaust Pipe For Cutting
Before you start cutting the exhaust pipe with a Sawzall, it’s important to prepare the pipe properly. Here are some steps to follow:
Step 1: Remove any Obstructions
Make sure there are no obstructions in the way of the exhaust pipe that could interfere with the cutting process. This includes any brackets, hangers, or clamps that are holding the pipe in place.
Step 2: Clean the Area
Use a wire brush or sandpaper to clean the area around the exhaust pipe where you will be cutting. This will remove any rust, dirt, or debris that could damage the blade or interfere with the cutting process.
Step 3: Measure and Mark
Measure and mark the area where you want to cut the exhaust pipe. Use a measuring tape and a marker to make a straight line around the circumference of the pipe. This will help you make a clean and precise cut.
Step 4: Protect Yourself
Wear safety glasses and hearing protection before starting the cutting process. This will protect your eyes and ears from any debris or noise generated during the cutting process.
Step 5: Secure the Pipe
Secure the exhaust pipe in place using a bench vise or clamp. This will prevent it from moving or wobbling during the cutting process, which can affect the accuracy of your cut.
By following these steps, you can prepare your exhaust pipe for cutting with a Sawzall and ensure that you get a clean and precise cut.
Finishing Touches And Safety Precautions
After you have finished cutting your exhaust pipe, it’s important to take some finishing touches and safety precautions. Here are some tips to help you do this:
1. Wear Protective Gear
Make sure to wear protective gear such as gloves, safety glasses, and a dust mask while cutting and finishing your exhaust pipe. This will help to prevent any injuries or exposure to harmful dust particles.
2. Inspect the Cut
After cutting the exhaust pipe, inspect the cut for any rough edges or burrs. Use sandpaper or a file to smooth out any rough spots and ensure a clean cut.
3. Check for Leaks
Before installing the new exhaust system, check for any leaks by starting the engine and checking for any unusual noises or smells. If you notice any leaks, make sure to fix them before driving your car.
4. Dispose of Waste Properly
Dispose of any waste materials properly, such as metal scraps or used blades. Make sure to follow proper disposal guidelines in your area.
By following these finishing touches and safety precautions, you can ensure that your exhaust pipe is cut properly and safely.