Cut Metal Conduit Without Damaging It - Here's How

Installing metal conduit for electrical wiring or plumbing systems often requires making precise cuts to customize the piping to your specific project. While metal conduit is durable, cutting it does require care and the right tools to avoid distorting or damaging the material. With some basic safety precautions and the correct technique, you can learn how to cut metal conduit cleanly and professionally.

With the right preparation and tools, you can achieve clean, undistorted cuts to metal conduit that will allow for smooth installation and wiring. Let's get started!

Tools You'll Need

Cutting metal conduit properly requires having the right tools for the job. Here are the basic tools you'll need:

• Hacksaw - A metal hacksaw with a sharp blade is essential for cleanly cutting conduit.
• Bench vise or cutting jig - These hold the conduit securely as you cut.
• Tape measure - To accurately measure and mark the cut line.
• Marker - For clearly marking the cut line.
• Metal file - For smoothing cut edges.
• Work gloves - To protect your hands from sharp edges.

Safety gear like gloves and eye protection are also recommended. Choose a hacksaw with the right blade length and tooth count for the diameter of conduit you are working with.

Measuring and Marking Cut Lines

Before making any cuts, you'll want to measure and mark where the cut should be made. Consider any 90-degree angles or bends in your conduit run when measuring the length you need to cut. It's better to cut a little long than too short.

Use a tape measure to precisely measure the length you want to cut. Then use a marker to cleanly mark a straight cutting line around the full circumference of the conduit. Making sure your cut line is nice and straight will result in a clean cut.

Securing the Conduit

Cutting metal conduit cleanly requires holding it very steady and secure as you saw. Attempting to cut freehand increases the risk of the conduit bending or the cut veering off-line.

Use a bench vise or a cutting jig specifically made for conduit to firmly grip and hold the conduit as you cut. Tighten securely but don't over-tighten, as this can damage the pipe. The conduit should be fully supported close to the cut line.

Bending Before Cutting

Bending the conduit slightly before making your cut will help create a clean, undistorted cut. Here's why:

• The bend relieves internal stress in the metal.
• When released after cutting, the metal will flex back to its original form.
• This prevents deforming or crimping from residual stress.

Use your hands or a conduit bender to apply a slight 5-10 degree bend before securing in place to cut. This pre-bend makes all the difference in getting a perfect cut.

Cutting Conduit With and Without Wires

The technique for cutting conduit will vary slightly depending on whether you are cutting a piece of conduit with wires already pulled through it or one without wires:

Without Wires

Cutting empty conduit is more straightforward. Secure it in a vise, pre-bend slightly, and cut using smooth back-and-forth motions with a hacksaw. Let the blade do the work - forcing it can bend the pipe or dull the blade prematurely.

With Wires

With wires inside, support the conduit near the cut so it doesn't twist and pull the wires. You may need to feed some slack wire through to prevent it from getting bound or pulled out while cutting. Also go slower to avoid shifting the wires around.

Other Cutting Methods

While a hacksaw is the most common tool for cutting conduit, you can also use other power tools:

• Bandsaw - Quickly cuts conduit but requires proper blade and expertise.
• Angle grinder - Good for quick cuts but causes more sparks and noise.

Each has pros and cons to weigh based on your specific needs and experience level when cutting metal conduit.

Safety Tips

Working with metal conduit requires taking precautions to avoid potential injuries:

• Wear thick work gloves to protect your hands from sharp cut edges.
• Double check conduit for any sharp edges or burrs after cutting.
• Keep your work area clear to prevent accidents with power tools.

It's also a good idea to wear eye protection when cutting conduit. Follow safe practices for each power tool you use as well.

Achieving Precise, Straight Cuts

Taking care with each step of the process will ensure you end up with clean precise conduit cuts:

• Carefully measure and mark cut lines.
• Secure conduit to prevent bending while cutting.
• Use a metal file to smooth any small uneven edges.

Rushing the cutting process can result in annoying bends, uneven ends, or burrs that hamper installation and wiring. Take your time to get cuts done right.

Opting to cut your own metal conduit rather than buying precut pieces offers significant cost savings. Pre-cut lengths of conduit can be very expensive at hardware stores.

While you'll have some initial investment in tools like a good hacksaw and vise, they will pay for themselves after using them for a few conduit cutting projects. Plus you'll gain a handy metalworking skill!

Cutting metal conduit is a relatively easy job. Follow these steps for smooth, undamaged cuts that will make wiring installation a breeze. Let us know if you have any other tips for cleanly cutting conduit!