How To Cut Flex Metal Conduit

How to Cut Flex Metal Conduit: A Comprehensive Guide

Cutting flex metal conduit might seem straightforward, but improper techniques can lead to damaged conduit, sharp edges, and even injury. This comprehensive guide will walk you through the safest and most effective methods, ensuring a clean, professional cut every time. This article covers the necessary tools, safety precautions, and step-by-step instructions for various cutting scenarios. Understanding how to properly cut flex conduit is crucial for any electrical work involving flexible metal tubing.

Tools You'll Need

Before you begin, gather the necessary tools. Having everything prepared beforehand ensures a smoother and safer process. You'll need:

• A hacksaw: A fine-toothed hacksaw is ideal for clean cuts on smaller diameter conduits. The finer the teeth, the cleaner the cut.
• A reciprocating saw (Sawzall): For larger diameter conduits or faster cutting, a reciprocating saw with a metal-cutting blade is efficient. Choose a blade with the appropriate teeth per inch (TPI) for the metal thickness.
• A pipe cutter (optional): While not essential, a pipe cutter can provide a cleaner cut, especially for thicker conduit. However, it requires more effort and might not be suitable for all conduit types.
• Safety glasses: Protecting your eyes from flying metal fragments is paramount.
• Work gloves: Gloves protect your hands from sharp edges and potential abrasions.
• Measuring tape: Ensure accurate measurements before cutting to avoid waste.
• Metal file or deburring tool: Removing burrs after cutting is vital for safety and to prevent damage to cables.

Safety First: Essential Precautions

Safety should always be your top priority when working with any tools, especially when cutting metal. These precautions are critical:

• Always wear safety glasses: This is non-negotiable. Flying metal shards can cause serious eye injuries.
• Use work gloves: These protect your hands from cuts and abrasions.
• Ensure proper ventilation: Cutting metal can produce fumes. Work in a well-ventilated area or wear a respirator if necessary.
• Secure the conduit: Use a vise or clamps to hold the conduit firmly in place while cutting. This prevents the conduit from moving unexpectedly and causing injury.
• Cut away from yourself and others: Always direct the cut away from your body and anyone nearby.
• Dispose of waste properly: Sharp metal scraps should be disposed of responsibly in a designated container.

How to Cut Flex Metal Conduit: Step-by-Step Instructions

The method you choose depends on the conduit's diameter and your available tools. Here's a guide for each method:

Using a Hacksaw

1. Measure and mark: Use a measuring tape to accurately mark the cutting point on the conduit.
2. Secure the conduit: Clamp the conduit firmly in a vise or use a sturdy work surface to hold it securely.
3. Cut slowly and steadily: Use a fine-toothed hacksaw and apply even pressure. Avoid rushing, as this can lead to a jagged cut. Allow the saw to do the work; avoid excessive force.
4. Deburr the edges: After cutting, use a metal file or deburring tool to remove any sharp edges. This prevents damage to cables and ensures safety.

Using a Reciprocating Saw (Sawzall)

1. Measure and mark: Accurately mark the cutting point.
2. Secure the conduit: Clamp the conduit securely.
3. Choose the right blade: Select a metal-cutting blade appropriate for the conduit's thickness.
4. Cut carefully: Make a smooth, controlled cut. Avoid excessive pressure to prevent the blade from binding.
5. Deburr the edges: Use a file or deburring tool to remove any burrs or sharp edges.

Using a Pipe Cutter (Optional)

1. Position the cutter: Place the pipe cutter around the conduit at the marked point.
2. Rotate and tighten: Gradually tighten the cutter, rotating it around the conduit. Continue until the conduit is severed.
3. Deburr the edges: File away any sharp edges.

Regardless of the method used, always remember to deburr the edges. This simple step greatly improves safety and helps prevent damage to the wires running through the conduit. Choosing the right tool and following these steps ensures a clean, safe, and efficient cut every time you need to work with flex metal conduit.