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Cutting a metal pipe properly depends on the type of pipe (steel, stainless steel, aluminum, copper, etc.) and the tools available. Here’s a step-by-step guide using different methods:

1. Using a Hacksaw (Manual Method)
Best for: Thin-walled metal pipes, small jobs
Steps:

Secure the pipe using a vise or clamps to prevent movement.
Mark the cutting line using a marker or chalk.
Use a hacksaw with a fine-toothed blade (18-32 TPI) for a smooth cut.
Apply steady pressure and use long, even strokes to cut through the pipe.
Smooth the edges with a file or sandpaper.
2. Using a Pipe Cutter (for Copper, Aluminum, or Thin-Walled Pipes)
Best for: Precise cuts on small-diameter pipes
Steps:

Place the pipe cutter around the pipe at the marked cut line.
Tighten the cutter and rotate it around the pipe.
Gradually tighten the cutter after each rotation until the pipe is cut.
Deburr the edges with a reamer or sandpaper.
3. Using an Angle Grinder (for Thick Metal Pipes)
Best for: Quick, efficient cuts on thick metal pipes
Steps:

Secure the pipe in a vise.
Use a cutting disc suitable for metal (abrasive or diamond blade).
Wear safety goggles, gloves, and a mask.
Hold the grinder with both hands and cut along the marked line.
Smooth rough edges with a grinding disc.
4. Using a Reciprocating Saw (Sawzall)
Best for: Cutting large-diameter or installed pipes
Steps:

Use a metal-cutting blade (10-24 TPI).
Secure the pipe or support it with clamps.
Start the saw at a low speed, then increase as needed.
Apply steady pressure but avoid forcing the blade.
Clean up burrs with a file or grinder.
5. Using a Chop Saw or Bandsaw (for Precision and Production Work)
Best for: High-volume or precision cutting in workshops
Steps:

Place the pipe in the saw’s clamp.
Use a metal-cutting blade or band.
Turn on the saw and slowly lower the blade into the pipe.
Smooth the edges as needed.
Safety Tips:
Always wear safety gear (gloves, goggles, ear protection).
Secure the pipe properly before cutting.
Use the right blade or disc for the material.
Keep hands clear of the cutting area.

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