What’s the best way to cut threaded rod?

Threaded rod or threaded bar is used in a wide variety of construction and DIY projects, mainly due to its versatility and cost-effectiveness. However, when it comes to cutting it to size, it is not immediately clear what the best method to use is, especially if one has a lot of them to cut. In this post, we explore the pros and cons of using different cutting methods and try to settle on the best way to cut threaded bar for different users.

Using a Hacksaw

The first and most economical method one can use to cut threaded rod is to use a hacksaw. The hacksaw itself is a common, inexpensive metal-cutting hand tool that many people already have in their toolbox. It can be used to cut threaded rod, but only if you don't have too many cuts to make. Using a hacksaw to cut threaded rod is relatively time consuming and physically demanding, so it is not our preferred method especially if other options are available.

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Using a Jigsaw

The jigsaw can be seen as the powered equivalent of the manual hacksaw. It has been designed to be used to cut through a range of different materials including metal. However, a special metal-cutting blade or carbide blade (in the case of stainless steel) is needed to make metal cuts. Even so, the jigsaw blade will still get very hot, so it will need time to cool down periodically to prevent it from becoming damaged. However, constantly stopping to allow the blade time to cool can significantly slow down the cutting process. One method to get around this inefficiency is to use several jigsaw blades in succession, changing to a cool one after doing a limited amount of cutting. This will prevent any single blade from overheating and can help speed up the cutting process overall.

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Using an Angle Grinder

One method that is particularly popular when it comes to cutting threaded rod is to use an angle grinder. Its popularity stems mostly from the fact that angle grinders are primarily designed for metal-working so they can cut through a metal rod relatively quickly. In addition, angle grinders are a common power tool and many people already have one in their tool box. To cut threaded rod with an angle grinder, you will need a metal-cut off wheel. Angle grinders can be dangerous if not used carefully, so extra care must be taken when using them to cut threaded rod.

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Using a Manual Rod Cutter

A less popular way to cut threaded rod is to use a manual rod cutter, which is a specialised tool that is specifically designed for the task. Unlike the previous methods that involve a sawing action, a manual rod cutter uses a shearing action to make the cut. Their major advantages are that they are quiet to use and produce a burr-free end that is immediately ready to accept a nut. However, the main reason this method is not more popular is that the tool tends to be (unreasonably!?) expensive. In addition, the manual rod cutter is limited to cutting only certain rod diameters, such as 6mm, 8mm, and 10mm, depending on the die size used. This tends to restrict the cutting method to those that need to cut a lot of a particular size of threaded rod or those that use the tool as part of their trade.

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Using a Powered Rod Cutter

Similar to a manual rod cutter, a powered rod cutter cuts threaded rods by shearing action. Once again, this shearing method usually produces a burr-free end that is immediately ready to accept a nut. Unlike 'sawing' power tools, the powered rod cutter also does not create chips or sparks and is very quiet when operating. However, the rod-cutting machine tends to be quite heavy due to its high-powered motor. In addition, different dies are needed to accommodate different-sized threaded bars, and changing the die requires the use of an Allen key. This slows down the whole cutting process especially if a lot of different-sized threaded rods need cutting. Finally, like the manual rod cutter, the powered version is only designed to cut a certain range of rod sizes, for example, the DeWalt DCS350 only cuts rod sizes from M6 to M12.

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Using a Metal-Cutting Band Saw

The final way discussed here to cut threaded rod is through the use of a metal-cutting band saw which uses a band or ring of blade that rotates continuously through the cutting interface. The band saw blade is usually made of high-speed steel, which can withstand the high heat generated during the cutting process. This is helped by the continuous movement of the blade band through the cutting position which also allows it time to cool off as it rotates. For this reason, the metal-cutting band saw obviates the need for blade-cooling downtime and can cut through various materials, including threaded rod, quickly and efficiently. As for negatives, this type of band saw can be quite expensive and bulky, so one needs to be cutting a large number of rods or other metal work in order to justify buying one. Additionally, metal-cutting band saws typically produce a significant amount of noise and metal shavings making them more inconvenient to use than some of the other cutting tools. 

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Conclusion

Ultimately, the best method to cut threaded bar depends on your specific situation. In particular, the number of threaded rods that need cutting and the tools you have available or are willing to buy, are the key factors that determine how best to go about cutting threaded rod. If you only have one or two rods to cut, a hacksaw or jigsaw is probably sufficient. However, if you have many rods to cut or cutting threaded bar is part of your trade, a manual or powered rod cutter, or a metal-cutting band saw is likely going to be the faster, more practical solution.