How to Cut Flex Metal Conduit

Flex metal conduit is an excellent tool for electricians working in tight spaces where traditional rigid conduits cannot fit. However, cutting it can be a challenge for some. In this blog post, we’ll cover everything you need to know about how to cut flex metal conduit in 11 easy steps.

How to Cut Flex Metal Conduit

Whether you’re a seasoned electrician or just starting in the industry, this guide is for you. We’ll cover everything from the tools you need to the best techniques for cutting flex metal conduits. So, let’s get started.

11 Step-by-step Instructions on How to Cut Flex Metal Conduit

Step 1: Gather Your Materials

Before you start, make sure you have all the needed equipment. You will need a pair of pliers, a hacksaw, a permanent marker, a tape measure, and a deburring tool. Having these tools on hand will make the process of cutting flex metal conduits much easier. It’s also handy to have a pair of safety glasses and gloves to protect your eyes and hands. It’s always better to be safe than sorry. But if you’re not comfortable with any of these tools, it is best to reach out to a professional.

Step 2: Measure Your Conduit

Next, measure the length of the conduit that you need. Use the tape measure to measure the distance and mark it with the permanent marker. This step is crucial because it helps ensure that you cut the right amount of conduit without wasting any. It’s also important to ensure that your measurements are accurate. This will help you avoid mistakes that could prove costly. This is especially important if you’re going to be using the conduit for a specific application.

Step 3: Mark the Cut Points

Now that you have the correct length, mark the points where you will need to cut. Make sure to place the marks about 1 inch from both ends of the conduit. This gives you enough space to use a hacksaw without damaging it. It’s always a good idea to double-check that the marks are accurate and aligned with your measurements.

Use a Hacksaw Without Damaging

Step 3: Put on Your Safety Gear

Cutting flex metal conduit can create a lot of sharp edges and metal shavings, so make sure you have on hand some safety gear like safety glasses and gloves. This gear will protect you from getting injured while working.

But even with safety glasses, you should still be careful when cutting the conduit. Metal shavings can cause serious eye damage if they come into contact with your eyes. It’s also a good idea to work on a flat, stable surface. This will help ensure that the conduit won’t slip while you’re cutting it.

Step 4: Score the Conduit

Using a permanent marker make a mark where you will be cutting your flex metal conduit. Then, take the hacksaw and score the conduit along this line. You should make numerous grooves to make sure that the groove is deep enough before the next step. But make sure that you don’t cut into the conduit too deeply. This could weaken the integrity of the pipe and create a dangerous situation.

Step 5: Secure the Conduit

Place the flex metal conduit securely in a vice to prevent it from slipping while you’re cutting it. It’s important that you take this step seriously as this ensures that the conduit will stay put and not move around, making it easier to cut. It also ensures that you don’t make any mistakes. Once the conduit is secured, you can start cutting it with a hacksaw. But it’s important to remember that you should always use a hacksaw specifically designed for cutting metal.

Step 6: Start Cutting

With the hacksaw, make the first cut on the flex metal conduit along the scoreline. Use a back-and-forth motion with the saw to make a clean and straight cut. Make sure that you start with a manageable section of the conduit. You can always go back and cut another section if you need to. You should also be careful not to apply too much pressure while cutting. This could cause the hacksaw to break off, leaving you with a jagged edge on your conduit.

Step 7: Smooth the Cut

After you’re finished cutting, use a deburring tool to smooth out the edges of the conduit that you cut. This is important because it helps remove any rough spots that can lead to scratches and cuts. Smooth edges make the conduct safer to work with as well. It’s also important to note that deburring should only be done on metal conduits. It shouldn’t be used on plastic or other types of materials. This can cause damage to the material.

Use a Deburring Tool to Smooth Out the Edges

Step 8: Measure the Length Again

After deburring, measure the length of the flex metal conduit again to ensure that it is the correct length. This step is essential as it will help you prevent this conduit from being the wrong length, which can lead to mistakes in your job. This is especially important if you’re using the conduit for a specific application. It can also help you save time and money in the long run.

Step 9: Repeat the Process

Repeat these steps until you have cut all the conduit sections that you need. Always remember to deburr after each cut to make sure that the conduit is safe and easy to work with. It’s also important to remember to always use a hacksaw specifically designed for metal, as it is the best way to ensure that you get a clean and straight cut. This will help you save time and energy in the long run.

Step 10: Finishing Up

After you’re finished cutting the conduit, clean up the scrap metal pieces you’ve made and put your safety gear away. This ensures that your workspace is safe, clean and ready for your next project.

But don’t forget to put the scrap metal in a designated bin or bag. This will help you keep your workspace organized and prevent accidents. If you’re done with the project and no longer need the conduit, make sure to recycle it. This is important for keeping our environment clean and healthy.

Step 11: Utilize the Cut Conduit

Finally, put the conduit to use. Whether it’s for electrical work, plumbing, or any other application, use your newly cut flex metal conduit, knowing that you have done an excellent job since you’ve followed these 11 steps on how to cut flex metal conduit. It is also a good idea to use the conduit with other components for a secure and tight fit. By following these steps, you’ll have a safe and reliable conduit that will last for years.

Frequently Asked Questions

Q: What type of hacksaw should I use to cut flex metal conduit?

A: It’s best to use a hacksaw with at least 32 teethes per inch (TPI) for the best results when cutting flex metal conduit. This type of hacksaw blade is designed specifically for cutting through hard metals like steel and aluminum, making it ideal for this job.

Q: Is a deburring tool necessary?

A: Yes, a deburring tool is essential as it will help you smooth out the edges of the conduit after you finish cutting it. This is important as it helps prevent any injuries due to sharp or rough edges and also makes the conduit safer and easier to work with.

Q: What other safety gear should I use?

A: It’s a good idea to have safety glasses, gloves, and a flat, stable surface when cutting flex metal conduit. Safety glasses are especially important as they will protect your eyes from metal shavings and dust created by the cutting process.

Gloves will also help keep your hands safe from any sharp edges or debris that may be present while you’re working. Finally, a flat, stable surface will ensure that the conduit doesn’t slip around while you’re cutting it. By following these safety tips you can ensure that your job goes smoothly and safely.

Q: Do I Need to Measure the Conduit Length After Cutting?

A: Yes, it is important to measure the length of the conduit after you’ve finished cutting it. This will help make sure that you cut the conduit to the correct size and prevent any mistakes in your job. It’s also a good idea to double check this measurement before using the conduit for its

Important to Measure the Length


Cutting flex metal conduits may seem daunting, but by following these simple steps, you can do it with ease. Always remember to measure, mark, secure, cut, smooth, and measure again. Make sure to take the necessary precautions by wearing protective gear and having the right tools.

With these 11 steps on how to cut flex metal conduit, you’ll have all you need to make the perfect cut every time. So, the next time you’re working with a flex metal conduit, don’t let the cutting process slow you down. Use this guide, and you’ll be a pro in no time.

You Can Check It Out To Cut Exhaust Pipe Without Saw

Photo of author

Enrique Howard

Hi, I am Enrique. I started my professional life as a handyman and did a lot of external and internal repair of home and office with a little bit of electric and plumbing support. I have extensive experience in tools testing such as drilling, turning, milling, and non-conventional machining like EDM. So let me help you on your journey towards becoming an enlightened DIYer with amazing tools that you can use on your project.

Leave a Comment