If you are planning on cutting metal using a reciprocating saw, there are a few important tips you should keep in mind to ensure a safe and effective process. First and foremost, make sure you wear eye and ear protection, and sturdy gloves to protect yourself from flying offcuts and chips.
Choosing the right blade is critical to the success of your project. A blade with 20-24 teeth per inch is the best recommendation for thin metal, while 10-18 teeth per inch works well for medium-thickness metal. For very thick metal, a blade with around 8 teeth per inch will provide the best results. Investing in a bi-metal saw blade set with a selection of blades suitable for a range of commonly performed projects is a wise choice.
Using a longer blade is helpful for flush cutting, as it will bend to enable a greater proportion of the cutting edge to ride flat. If cutting thinner materials, a smaller blade will help limit 'waggle' during use; usually, the blade should only be a couple of inches longer than the depth of cut required.
Inserting the blade into the saw in a way that best suits the application can help make the process smoother. For example, if cutting through a material that is flush to the floor, it can be useful to insert the blade with the teeth facing upwards and then switch the orientation of the tool (flip it upside-down) so the handle does not get in the way.
Setting the saw to a slower speed than for wood cutting will extend the blade's life and provide more control and precision. Adjust the shoe to ensure it is set at the most appropriate point on the blade.
To start cutting, place the blade where the cut will be, using the shoe as a pivot or fulcrum to help guide the blade until it gains purchase in the metal. Slowly squeeze the trigger and keep a firm hold on the tool housing. Changing the cutting angle by lowering or raising the trigger hand (in relation to the workpiece) can speed up the cutting time.
Once the cut is complete, let go of the trigger and withdraw the blade back through the cut. It is important to prolong the life of your reciprocating saw blades by maintaining them properly. If a saw blade becomes buckled, it can be easily straightened by placing it on a flat surface, putting a flat piece of wood over the damaged area, and hitting the wood a few times with a hammer.
If a blade has become too worn to cut metal, it can often be repurposed for use in cutting plastics. By following these tips, you can ensure safe and effective metal cutting with your reciprocating saw.
