How do you cut metal by hand?

How do you cut metal by hand? - Fix It Cape Town

Metalworking is a craft that requires finesse, precision, and the right tools. While modern technology has brought us power tools and lasers, there is still something special about the art of hand-cutting metal. Whether you are a jewelry maker or a DIY enthusiast looking to Repair or shape metal, this guide will walk you through the steps of cutting metal by hand using various hand tools like hacksaws and snips.

Understanding the Process

Before diving into the different tools and techniques, it’s important to have a basic understanding of the hand-cutting process. Hand-cutting metal involves using hand tools to shape or separate metal pieces. This can be done by sawing through the metal using a hacksaw, or using snips to cut smaller pieces, such as wires or thin sheets of metal.

There are several factors to consider when hand-cutting metal:

  1. Safety: Always prioritize safety when working with metal. Wear protective gloves, safety goggles, and a dust mask to prevent any accidents or inhalation of metal particles.
  2. Material: Different types of metal require different cutting techniques. Understand the properties of the metal you are working with to choose the appropriate tools and methods.
  3. Precision: Hand-cutting requires skill and precision. Take your time and measure accurately to ensure clean cuts and minimal waste.

Now, let’s dive into the specific hand tools and techniques for cutting metal by hand.

Hacksaws: Cutting through Metal like a Pro

A hacksaw is a versatile hand tool that can be used to cut through various types of metal. Here’s a step-by-step guide to using a hacksaw:

  1. Choose the Right Blade: Select a hacksaw blade with the appropriate number of teeth per inch (TPI) for your metal. The higher the TPI, the smoother the cut. For thinner metals, opt for a blade with higher TPI, while thicker metals may require a lower TPI blade.
  2. Secure the Metal: Use a clamp or vise to secure the metal piece you want to cut. This will prevent it from moving and ensure a more accurate cut.
  3. Mark Your Cutting Line: Use a marker or scribe to mark the line where you want to make the cut. Precise marking will help guide the saw blade.
  4. Start Sawing: Hold the hacksaw firmly with one hand and place the blade at the starting point of the cut. Apply light pressure and use long, smooth strokes to saw through the metal. Let the saw do the work and avoid forcing it.
  5. Cooling and Lubrication: To prevent overheating and extend the life of the blade, apply cutting fluid or lubricant to the cutting area. This will keep the blade cool and reduce friction.
  6. Finishing touches: After completing the cut, use a file to smooth any rough edges or burrs for a clean, finished look.

Snips: A Perfect Tool for Precise Cuts

Snips, also known as tin snips or aviation snips, are hand tools specifically designed for cutting sheet metal. Here’s how to use snips effectively:

  1. Select the Right Snips: Snips come in different types, each designed for specific cutting tasks. Straight-cut snips are used for straight cuts, while left-cut and right-cut snips are used for making curves in specific directions. Choose the appropriate snips based on your desired cut.
  2. Secure the Metal: Similar to using a hacksaw, secure the metal piece you want to cut using a clamp or vise.
  3. Mark Your Cutting Line: Use a marker or scribe to clearly mark the line where you want to make the cut. This will serve as a guide for the snips.
  4. Start Cutting: Hold the snips firmly, with your dominant hand on the handle and the other hand supporting the metal. Position the snips over the marked line and apply steady pressure to engage the blades. Close the handles to cut through the metal. It’s important to make gradual cuts to prevent the snips from getting stuck or causing damage to the metal.
  5. Finishing touches: After cutting the metal, use a file to smooth any sharp edges or burrs.

Frequently Asked Questions

1. What types of metal can be cut by hand?

A variety of metals can be cut by hand, including steel, aluminum, copper, and brass. The choice of tools and techniques may vary depending on the thickness and hardness of the metal.

2. How do I choose the right blade for my hacksaw?

Consider the thickness of the metal when choosing a hacksaw blade. Thinner metals require blades with higher TPI, while thicker metals need blades with lower TPI. Experiment with different blades to find the one that provides the best balance between speed and smoothness.

3. Can I use snips to cut through thick metal?

Snips are primarily designed for cutting thin sheet metal. If you need to cut through thicker metal, it is advisable to use a hacksaw or another appropriate cutting tool.

4. How can I prevent overheating when cutting metal by hand?

Applying cutting fluid or lubricant to the cutting area helps dissipate heat and reduce friction. This prevents the blade from overheating and ensures smoother cuts.


Hand-cutting metal is a skill that requires practice, patience, and the right tools. By following the steps outlined in this guide, you can successfully cut through metal by hand using hacksaws and snips. Always prioritize safety and take the time to choose the appropriate tools and techniques for the type of metal you are working with. With practice and attention to detail, you can master the art of hand-cutting metal and create beautiful jewelry or complete essential repairs with precision and finesse.

Handyman Cape Town

Open chat
Contact us now
Scan the code
Hello 👋
Can we help you get a free quote?