The traditional handsaw for cutting metal, a hacksaw has extra-hard teeth, a sturdy frame
with a D-shaped handle, and a narrow blade from 8 to 16 inches long, with 14 to 32 teeth
per inch (tpi). The blade can be installed to cut on either the push or pull stroke.
Using a Hacksaw
Select a blade appropriate for the material you plan to cut. A coarse-toothed (14 to 18
tpi) blade can handle thick material, solid rod, and all soft metals. Hard metals, thin
stock, and pipe with wall thicknesses less than 1/16 inch require a blade with 32 tpi.
Fasten the blade to the frame. Apply enough tension so the blade sounds an audible hum
when you tap it. In some cases it may help to file a small groove in the surface to
serve as a guide for starting a cut. When cutting, angle the saw to keep at least
three teeth in contact with the material. Lubricate the blade with light oil, except
when cutting cast iron.
If the blade clogs while cutting, switch to a blade with coarser teeth. If the cut
line drifts, add more blade tension or install a fresh blade. If the blade breaks while
cutting, start a new blade at the opposite end of the layout line and work toward the
starting cut. This prevents a new blade from binding (getting "stuck") in the old cut
and breaking.
Cutting in Tight Places
If there is not enough room to move the saw normally, try inverting the blade. Simply
remove the blade, and reinstall it with the teeth in the opposite direction, trapping
the workpiece in the frame if necessary.
Cutting Sheet Metal
To cut sheet metal, clamp the workpiece between two pieces of wood and hold the assembly
in a vise. Cut through both the wood and metal. Use a miter box to ensure efficient,
accurate crosscuts in pipe.
Purchasing
Hacksaw frames come in two styles: a fixed version for either 10- or 12-inch-long blades
and an adjustable version that takes blades from 8 to 16 inches long. For versatility,
choose the adjustable version.
Substitutes
Alternatives to the hacksaw include the cold chisel, aviation snips and powered saber saw.
Caution
- When supporting a piece of metal with your hand, wear gloves and keep your hand out of
the path of the cut. If the stock is heavy, support the waste.
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