How to Cut Steel Tubing

Are you looking for a quick and easy way to cut steel tubing? You’ve come to the right place! In this guide, we’ll teach you the best techniques, tools, safety tips and more that you need to know in order to become an expert at cutting steel tubing. Our comprehensive approach will help take any stress or confusion out of the process so that you can confidently carry out your project with ease. So let’s get started!

How to Cut Steel Tubing

However, with the right strategies and tips in place, anyone can be successful in achieving their desired outcome – from simple tasks such as making pipe brackets to more complex projects that involve intricate cuts. In this blog post, we’ll look at different techniques and tools used when cutting steel tubing so that whatever your project may be, you have clear instructions on how to cut steel tubing.

Why May You Want to Cut Steel Tubing?

1 . To Modify Length

One major reason for cutting steel tubing is to change its length. Steel tubing often comes in standard lengths, which may not always be suitable for a particular project or application. Cutting the tubing to the desired length allows it to fit perfectly and provides a cleaner look.

2 . To Create Angles and Shapes

Another reason to cut steel tubing is to create angles and shapes that are needed for a project. For instance, cutting a section of steel tubing at an angle can help in creating joints or connections between parts. In addition, cutting different lengths of steel tubes at precise angles allows for the construction of unique geometric shapes that may be required for specific applications.

3 . To Remove Damaged Sections

Steel tubing may become damaged due to various reasons, such as corrosion or wear and tear. In such cases, cutting the damaged sections of the tubing is necessary to maintain its structural integrity and prevent further damage. By removing the damaged portions and rejoining the remaining sections, you can restore the functionality of the steel tubing without having to replace it entirely.

 Remove Damaged Sections

4 . To Fit into Tight Spaces

Not all projects have ample space to work with, and sometimes you may need to cut steel tubing to fit into tight or confined areas. This is particularly important when working on structures such as buildings or vehicles, where precise measurements are crucial. Cutting the tubing allows it to be easily maneuvered into these spaces without compromising its structural stability.

5 . To Create Custom Pieces

Cutting steel tubing also offers the possibility of creating custom pieces that may not be readily available in the market. By cutting and joining different sections of tubing, you can create unique structures or components that are tailored to your specific needs. This gives you more control over your project and allows for creativity in design.

How to Cut Steel Tubing in 5 Easy Steps

Step 1: Gather the Necessary Tools

To start cutting steel tubing, you will need a few essential tools: a tube cutter, a metal file, safety glasses, and gloves. The tube cutter should have a blade specifically designed for cutting through steel tubes. Make sure to choose a metal file with fine teeth for smoothing out any rough edges once you are finished cutting. Safety glasses and gloves are essential protective gear to keep yourself safe from debris and sharp edges.

Step 2: Measure and Mark the Tubing

Before cutting the steel tubing, you will need to measure and mark where you want to make your cut. Using a tape measure, determine the desired length of your tube and mark it with a permanent marker. Make sure to double-check your measurements before moving on to the next step.

Step 3: Secure the Tubing in Place

To ensure a clean and precise cut, you will need to secure the steel tubing in place. Depending on the diameter of your tube, you can use a vise or clamps to hold it firmly. This step is crucial for smaller diameter tubes as they tend to move around while cutting. Make sure that the marked area is aligned with the blade of your tube cutter.

Step 4: Cut the Tubing

Now that your tubing is secured, it’s time to start cutting. Begin by rotating the tube cutter around the steel tube, applying firm and even pressure with each rotation. Make sure to keep the blade lined up with your marked area for a clean cut. Continue rotating until you have completely cut through the tube. For thicker tubes, you may need to make multiple passes with the tube cutter to achieve a clean cut.

Step 5: Smooth Out Any Rough Edges

After cutting the steel tubing, use a metal file to smooth out any rough edges. This step is essential for safety reasons as sharp edges can cause injuries. Gently run the metal file along the cut edge of the tube until it is smooth and free from burrs. Once complete, you can safely handle your newly cut steel tubing.

Some Extra Tips to Cut Steel Tubing

1 . Do Not Use Dull Blades

When it comes to cutting steel tubing, using sharp blades is crucial. A dull blade not only makes the process difficult, but it also results in a jagged and uneven cut. This can be dangerous as well as affect the structural integrity of the tubing. Make sure to regularly check your cutting tools and replace any dull blades.

2 . Use the Correct Tools

Using the correct tools is essential for a clean and precise cut. For cutting steel tubing, you can use a hacksaw, reciprocating saw, or chop saw. However, it’s important to select blades specifically designed for cutting steel. These will have fewer teeth per inch (TPI) and are made from stronger materials such as high-speed steel. Using the wrong type of blade can result in damage to the tubing and pose a safety hazard.

3 . Measure Twice, Cut Once

Before making any cuts on your steel tubing, be sure to measure it accurately. It’s always better to double-check your measurements before committing to a cut. This will help avoid any mistakes or wasted material. It’s also a good idea to mark the cutting line with a permanent marker for better precision.

4 . Secure the Tubing

To prevent any accidents, it’s important to secure the tubing before making any cuts. This can be done by using clamps or a vise grip. The tubing should be firmly held in place to prevent it from moving during the cutting process. This will ensure a straight and clean cut.

5 . Choose the Right Cutting Method

Depending on the thickness of the steel tubing and the type of cut you need, there are different cutting methods that can be used. For thinner tubing, a hacksaw or reciprocating saw may be sufficient. However, for thicker tubing, a chop saw with an abrasive blade or cold saw may be necessary for a smooth and precise cut.

Frequently Asked Questions

What Precautions Should I Take Before Cutting Steel Tubing?

Before cutting steel tubing, there are a few precautions you should take to ensure your safety and the quality of your cuts. Here are some tips to keep in mind: This includes safety glasses, gloves, and earplugs. Steel can produce sharp edges and metal shavings that may cause injury. Also, it is important to secure the tubing in place before cutting to prevent any movement that could result in an uneven cut or injury.

 Metal Shavings That May Cause Injury

What Tools Do I Need for Cutting Steel Tubing?

To cut steel tubing, you will need a few essential tools. These include a hacksaw, pipe cutter, angle grinder with a cutoff wheel, and a metal file. The type of tool you choose will depend on the thickness and size of your steel tubing. It is recommended to have multiple tools on hand in case one does not work as well as expected.

How Do I Cut Steel Tubing with a Hacksaw?

To cut steel tubing with a hacksaw, you will first need to secure the tube in place using clamps or a vise. Then, use a marker or chalk to mark where you want to make the cut. Next, carefully saw through the marked line using even and steady strokes. It is important to keep the saw blade perpendicular to the tubing for an even cut. Once you have completed cutting, use a metal file to smooth out any rough edges.

Cut Steel Tubing With a Hacksaw


Overall, cutting steel tubing for whatever construction or building project can be intimidating but with the proper knowledge and the right tools, it doesn’t have to be. As long as you are aware of your tube size requirements and the type of saw appropriate for the job, and use correct safety techniques, you can easily and quickly complete your project with great results.

Now you know how to cut steel tubing! So don’t be afraid to tackle those steel tubes! Get out there and give it a go–you may surprise yourself with how successful you can be in cutting steel tubing! And if you need questions answered or advice on the best tools to get started – consult an expert – they will be happy to help you out, every step of the way. Good luck!

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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.

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