How to Cut Metal Rod – The Easiest Way

The durability and strength of metal can be both a curse and a blessing at the same time. If you need to cut a metal rod for a DIY task or other projects, you need to be able to cut metal.

However, due to the sturdiness of metal, the usual craft tools you have at home might not do the trick. But how can you cut it without putting blood, sweat, and tears into it?

Read this article to find out how to cut metal rod in the easiest ways possible.

How to Cut Metal Rod – The Easiest Way

Using a Hacksaw

So you need a bunch of things in order to cut metal rods with the least amount of effort.

  • A hacksaw with 18 or 32-tooth blade
  • Lubricant spray
  • Chalk or something to mark
  • Measuring tape
LENOX Tools High-Tension Hacksaw, 12-inch (12132HT50), Blue
  • The LENOX hacksaw uses an I-beam construction, allowing the blade to tension up to 50,000 psi
  • Rubberized handles allow for confident handling, even in wet and cold environments
  • Hacksaw accepts any LENOX reciprocating saw blade to be used as a jab saw
  • LENOX hacksaw stores up to 5 extra 12-inch hacksaw blades in the I-beam
  • All hacksaw come with one 12-inch, 24 TPI hacksaw blade

Step 1: Secure the Rod

Before you cut the rod, you must secure it with a vise. Make sure you measure the length and mark the desired length with chalk or a marker. Then secure the metal rod and keep the marked rod at least two inches near the vise as it will vibrate less than it would if you kept it far from the grip of the vise.

Step 2: Lubricate the Rod

Next, thoroughly spray the marked area with a lubricant. This will ensure that it is easier to cut, and the cut is smooth.

Step 3: Put the Blade a Bit Farther from the Mark

Then you should place the hacksaw blade a little farther from the mark and prepare to cut. You might wonder why to place the blade away from the mark; this is because blades have a certain thickness.

This leads the blade to remove some materials from the metal. If you use the blade to cut from the middle of the mark, the piece may become shorter than needed. It is easy to remove materials but near impossible to add.

Using a hacksaw to cut metal easily requires both hands. As you are using a vise, place your dominant hand in the handle of the saw and your other hand at the front top part of the saw. Pull back the saw using as little pressure as possible as this is the first cut.

Step 4: Cut the Rod

Like files, saw blades cut when it is pushed forward. So as smoothly as possible, push the saw forward but use little to no pressure to pull it back. If you apply excess pressure to pull the saw back, it can result in an uneven cut.

Hence, to cut it efficiently, only apply pressure to move the saw forward in a long stroke, and be careful when pulling the hacksaw back.

Using Chop Saw with Abrasive Cutter

If you are not willing to put hours of manual labor and want maximum results with minimum effort, use a chop saw. You can easily cut through any metal, be it cast iron or alloy steel, with a chop saw with an abrasive cutter.

And you can very easily cut the metal rod with a chop saw because it has massive power to cut through thick pieces of metal rods, bars, or sheets. Although there are other types of saws that can cut through rods, a chainsaw distinguishes itself with its fast rotating abrasive blade to slice through a lot of hard metal at once.

So it cuts effectively and saves time. Another advantage of using chop saws with abrasive blades is that you can cut a lot of pieces of the same length by putting very little effort

DEWALT Chop Saw, Quick-Change, 14-Inch, Old Model (D28715)
  • Powerful 15 amp/5.5 HP (maximum motor HP) motor of the chop saw provides more overload capacity, increasing performance and durability
  • QUIK-CHANGE keyless blade change system of the metal chop saw increases productivity by providing the user the ability to change wheels without a wrench
  • Exclusive QUICK-FENCE of the metal cutting saw is a 45-degree, adjustable fence designed for fast and accurate angle cuts without using a wrench
  • QUICK-LOCK vise allows for fast clamping on different size materials to increase productivity
  • Ergonomically designed -inchD-inch handle provides a more comfortable hand position, reducing fatigue and increasing productivity

Using Circular Saw

You might not like the inflexibility of chop saws as it moves only up and down. If you want more flexibility, use a circular saw. Such saws allow you to move the saw at different angles. You can maneuver the blade and cut the material in any shape or size necessary.

In order to cut metal rods with this saw, mark the rod carefully with a chalk or marker, and then steadily place the rotating saw on the mark. Avoid pushing it abruptly and sharply as the blade can break and hurt you or cause other serious damage.

SKIL 15 Amp 7-1/4 Inch Circular Saw with Single Beam Laser Guide - 5280-01
  • Powerful 15-amp motor delivers 5 300-RPM for greater speed and faster cuts
  • 7-1 4-inch carbide-tipped blade included. Spindle lock for easy blade changes.
  • 51° bevel capacity with a positive stop at 45° for a wide variety of cuts
  • Dust blower keeps line-of-cut free of sawdust for improved visibility
  • Safety lock/guarded trigger and power-on indicator minimize accidental starts

Things You Need for Safety

For using power saws such as chop saws or circular saws, you need to be cautious and have the following item for safe handling of the saws.

  • Face shield
  • Goggles
  • Face mask
  • Ear protector
  • Chalk or marker

Final Words

There are many other ways to cut metal rods, but these three are the easiest way you can cut through metal rods.

While using hacksaw requires a lot of physical effort, it is the cheapest option here. But if time is more important to you and you have a greater load of work, it is best to opt for either a chop saw with an abrasive blade or a circular saw. But before working with any tools, remember, safety always comes first.

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