How to Cut a Bolt

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Learn how to cut a bolt with a hacksaw, power drill, or grinder with this step-by-step guide. Plus, find out what type of saw blade to use.

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Bolts are grade 8.8 and higher and have a tensile strength of at least 800 MPa. For most home handymen, a good quality grade 8.8 should suffice. A lower grade bolt will do the job if it’s not being used for a critical application, but it’s always best to err on the side of caution and go for a higher grade if you’re unsure.

Cutting a bolt is a relatively easy task that can be performed with just a few tools. In this article, we’ll show you how to cut a bolt using two different methods.

What You’ll Need

-A hacksaw or a power saw if the bolt is big
-A file
-A vise
-Safety goggles

1. Place the bolt in the vise and tighten it so it is held securely.
2. If you are using a hacksaw, put on your safety goggles and saw through the bolt, following the line you have marked.
3. If you are using a power saw, make sure the blade is the right size for the bolt and that it is securely attached. When you are ready, put on your safety goggles and cut through the bolt following your line.
4. Use the file to smooth any sharp edges on the end of the bolt so that it does not tear up anything it comes in contact with.

Step One: Measure the Length of the Cut

Knowing the measurement of the cut is important so you can determine how much of the bolt needs to be removed. For example, if you need a one-inch cut, then measure out one inch from the end of the bolt using a ruler. Once you have your measurement, use a pencil to mark that spot on the bolt.

Step Two: Mark the Cutting Line

Mark the cutting line on the bolt using a pencil or felt-tip pen. For best results, make the mark as close to the head of the bolt as possible. If you’re working with a short bolt, you may need to use a magnifying glass to help you see the cutting line clearly.

Use a measuring tape to find the center of the bolt, then make a dot at that point. Draw a line from one side of the bolt to the other, passing through the center dot. This will be your cutting line.

Step Three: Clamp the Bolt

Before you can cut the bolt, you need to secure it in a vise or clamp. This will help to hold the bolt steady while you’re cutting it. You want to make sure that the bolt is as level as possible in the vise or clamp so that your cuts are clean. Once the bolt is secured, you’re ready to start cutting.

Step Four: Cut the Bolt

Now that the drilling is complete, it’s time to cut the bolt. For this step, you will need a cutting tool. A saw or an angle grinder will work just fine. If using a saw, make sure that it is a fine-toothed blade to avoid damaging the surrounding material. When cutting, be sure to go slowly and steadily to ensure an even cut.

If using an angle grinder, be careful not to overheat the bolt as this can damage the surrounding material. Make sure that you have a good grip on the grinder and that you are cutting in a straight line. Again, go slowly and steadily to ensure an even cut.

Once the bolt is cut, remove it from the material and dispose of it properly.

Step Five: Remove the Cut Piece

Now that you have cut the bolt, you will need to remove the cut piece from the power drill. You can do this by using a pair of pliers. Grab the end of the cut piece of the bolt and pull it out of the power drill.

Step Six: Deburr the Edge

Now that you have a clean cut, it’s time to remove the sharpness from the edge of the bolt. This is called deburring, and it’s an important step in any cutting project. You can use a file, a grinding wheel, or a sanding disc to deburr the edge of your bolt. Once you’ve removed the sharpness, your bolt is ready to use.


Now that you know how to cut a bolt, there are a few things to keep in mind. Always wear safety glasses and gloves when working with power tools. If the bolt is too tough to cut with a hacksaw, try using a sawzall or an angle grinder. And when cutting through metal, always use a sharp blade to avoid accidents.


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