How to Cut Wire Without Wire Cutters

 

Regardless of whether the job you're on is big or small, a capable wire cutter is a good tool to have on hand. Wire cutters can help you make fast, clean cuts in most types of wire including copper, brass, steel, building wire, and others.

But what if you don't have a wire cutter handy? What are your options to get the wire cut to get the job completed? Realistically, trying to cut wire with something other than a good pair of wire cutters is not recommended. They're inexpensive and readily available so it's a good idea to simply invest in a well-made wire cutter. While it's not recommended, there are some alternative ways to cut wire without a wire cutter.

If the wire is relatively thin and pliable, it's possible to repeatedly bend it back and forth until the wire literally breaks. If the wire is too thick or jacketed, this process will definitely not work. However, if you're able to get the wire to break by repeatedly bending it, you've compromised the integrity of the wire. The area of the wire near to where the cut or break happened will suffer work-hardening, actually making that area of the wire stronger and harder than the rest of the wire. And, unfortunately, the wire will suffer deformation from the bending and will be unreliable and perform poorly after it separates.

It's possible to use a hacksaw to cut wire if no cutter is available. You'll want to use a blade with a high teeth-per-inch (TPI) count for as clean a cut as possible. Regardless of the TPI count, using a hacksaw to cut wire is difficult unless the wire has a large diameter. If it's a small, thin-diameter wire, you're more likely to deform and bend the wire too much before you're able to complete the cut through it.

If you're inclined to use scissors, nail clippers, shears, snips, or another tool not suited for the job, you're likely headed for unsatisfactory results. Scissors, clippers, and the like just aren't made to cut wire. Chances are you'll end up with dull scissors or clippers from trying to cut the wire, or worse—you'll completely damage or ruin the tool. These aren't sharp enough to cleanly cut wire, so the wire will end up being bent out of shape. And if you're able to make the cut, since it won't be clean, the integrity of the wire will be compromised and its performance unreliable. Since these types of tools aren't typically insulated, there's also a risk for an electrical shock if they're misused.

Melting the wire with a torch to cut it can certainly separate it into a couple of pieces, but regardless of how fine a flame the torch can produce, it will lead to more issues. The wire will certainly deform since it will likely melt where it's cut by the torch, not to mention it oxidizing very heavily as it heats up significantly. If the wire is insulated, you can expect burned, melted, and deformed insulation near where the cut was made.

As any seasoned contractor, tradesman, or experienced DIYer will tell you, having the right tools for the job usually ends with the best results. So, while you may be tempted to cut wires with a saw, scissors or some other ill-suited tool, resist that temptation. Invest in a quality pair of wire cutters and be sure you have them ready when you tackle that next job. You won't regret it!

 

The product statements contained in this guide are intended for general informational purposes only. Such product statements do not constitute a product recommendation or representation as to the appropriateness, accuracy, completeness, correctness or currentness of the information provided. Information provided in this guide does not replace the use by you of any manufacturer instructions, technical product manual, or other professional resource or adviser available to you. Always read, understand and follow all manufacturer instructions.