For me, using a hacksaw was an exercise in frustration. The blade would often jam in the cut, or break. And the resulting cut was usually rougher than I’d like. But, as I found out, there are some tips and tricks you can use to get the results you want from your hacksaw. The key to success starts with the tools and accessories. The first, and perhaps most important, thing to consider is your hacksaw frame. Upgrading to a high-tension frame, like the one you see here, makes all the difference. It’s a little more expensive, but the improved results prove its worth. Finally, I’ve learned it’s important to throw the blade away as soon as you notice it’s getting dull. There’s no point in fighting with a dull blade when a replacement is so inexpensive.
But the most helpful thing you can do is fully support the workpiece. I support a variety of workpieces. The key is to eliminate all vibration and movement as you push the saw into the cut. Like the rip fence on your table saw helps ensure a straight cut, a guide for your hacksaw can do the same. This can be as simple as a block of wood. A wood block nestled in angle iron helps guide the blade for a square cut.
You can also use two pieces of wood that “trap” the workpiece to prevent movement and guide the blade. Clamp a hinge between rabbeted guide blocks for a smooth, straight cut.
A couple of nuts and washers form a guide for cutting threaded rod and bolts to length.
Insert a dowel to get a cleaner cut and keep the tube from crimping. While a hacksaw isn’t usually considered a precision tool, you can tame this rough-cutting saw with the right equipment and techniques. With a little practice, you’ll be getting professional results — without all of the frustration.
