How do you cut metal with tools at home?

How do you cut metal with tools at home? - Fix It Cape Town

Metal cutting is an essential skill for DIYers, artisans, and even homeowners who want to take on various projects. While industrial tools such as plasma cutters and laser cutters offer precise and efficient metal cutting, they can be expensive and out of reach for many individuals. However, did you know that you can achieve accurate cuts in metal using common household tools like hacksaws? In this comprehensive guide, we will walk you through the process of cutting metal using hacksaws, providing you with the necessary knowledge to tackle your metal cutting projects with confidence.

Tools You Will Need

Before we dive into the techniques, let’s start by gathering the necessary tools for this DIY metal-cutting endeavor. Here are the common household tools you will need:

  1. Hacksaw: A versatile hand tool designed specifically for cutting metal. It consists of a frame and a removable blade. Make sure to choose a reliable hacksaw that’s comfortable to hold and has a replaceable blade.

  2. Bench Vise: An essential tool for securely holding the metal piece you’re working on. A bench vise mounted on a sturdy workbench allows for precise and controlled cutting.

  3. Marker or Metal Scribe: This tool will help you mark the area you want to cut on the metal surface.

  4. Safety Gear: Always prioritize safety! Use safety goggles to protect your eyes from metal shavings and debris, and wear work gloves to protect your hands.

Now that you have the necessary tools, let’s delve into the techniques of using a hacksaw to cut metal.

Technique 1: Marking the Cutting Line

Before you start cutting, it’s crucial to mark the area you want to cut on the metal surface. Use a marker or a metal scribe to create a clear and visible line. Ensure that the line is straight and accurate, as it will act as your guide throughout the cutting process.

Technique 2: Securing the Metal in a Bench Vise

To achieve precise and controlled cuts, it’s essential to secure the metal in a bench vise. The bench vise will hold the metal piece firmly in place, allowing you to focus on the cutting technique without worrying about the metal shifting or moving.

To secure the metal in the bench vise, follow these steps:

  1. Open the bench vise by turning the handle counterclockwise.

  2. Insert the metal piece between the jaws of the bench vise.

  3. Adjust the jaws until they are snug against the metal. Ensure that the metal is held securely without any wobbling or movement.

  4. Tighten the bench vise by turning the handle clockwise. Apply enough pressure to firmly grip the metal but avoid overtightening, as it may deform or damage the metal.

Technique 3: Selecting the Right Blade

Choosing the right blade for your hacksaw is crucial to ensure efficient metal cutting. Hacksaw blades come in different sizes and types, with varying numbers of teeth per inch (TPI). The TPI determines the speed and smoothness of your cuts. Here are some general guidelines for selecting the right blade:

  • Higher TPI blades (24 TPI or more) provide smoother cuts but are slower.

  • Lower TPI blades (14 TPI or less) are faster but may leave rougher edges.

Select a hacksaw blade with the appropriate TPI for your specific metal-cutting needs. For example, thinner metals may require a higher TPI blade, while thicker metals may require a lower TPI blade.

Technique 4: Cutting Technique

Now that you have everything set up, it’s time to start cutting the metal. Follow these steps for optimal results:

  1. Hold the hacksaw by the handle, ensuring a firm and comfortable grip.

  2. Position the hacksaw blade at the beginning of the marked cutting line.

  3. Apply light pressure and move the hacksaw back and forth in a smooth and controlled motion. Let the blade do the cutting work gradually.

  4. Maintain a steady pace and avoid applying excessive force, as it may cause the blade to break or the cuts to be imprecise.

  5. Keep your body in a stable position and use your arm muscles when cutting. This will help you maintain control and precision.

  6. Regularly pause during the cutting process to remove metal shavings and debris accumulated on the cutting line. Clearing the area will ensure a more accurate and efficient cutting process.


1. Can I cut any type of metal using a hacksaw?

Hacksaws are suitable for cutting various metals, including steel, aluminum, brass, and copper. However, keep in mind that harder metals may require more effort and patience to cut through.

2. How can I prevent the hacksaw blade from dulling quickly?

To prolong the life of your hacksaw blade, use cutting lubricants such as oil or cutting fluid. These lubricants reduce friction and heat, preventing the blade from dulling too quickly.

3. Are there any safety precautions I should take while cutting metal with a hacksaw?

Yes! Always wear safety goggles to protect your eyes from metal debris, and use work gloves to safeguard your hands. Additionally, ensure that the work area is well-lit and free from clutter to avoid accidents.


By mastering the art of cutting metal using common household tools like hacksaws, you can save on expensive industrial equipment and still achieve accurate cuts. Remember the importance of marking the cutting line, securing the metal in a bench vise, selecting the right blade, and applying proper cutting techniques. With practice, patience, and safety precautions, you’ll soon be capable of tackling various DIY metal-cutting projects with confidence. So go ahead, unleash your creativity, and embark on exciting ventures with the power of DIY metal cutting!

Handyman Cape Town

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