How To Cut a Screw Perfectly

For both seasoned professionals and casual DIYers, knowing how to cut screws is a valuable skill that can really come in handy. Maybe your new drawer pulls came with screws that are too long, or you need to remove a damaged screw from a project. Whatever the case, when you need to cut a screw, knowing the right techniques is key.

I’ve used all of the methods and tools discussed in this article, and they’ve each gotten me out of a tight spot more than once. Ahead find tips and how-to steps to cut a screw with help from Paul Ricalde from Paul’s Toolbox and Chris Bernacki from WnC Home Remodeling.

Should You Cut a Screw?

In most cases, it’s okay to cut screws, but you have to be careful not to damage it. Machine screws, which have tightly spaced threads, are at more risk of damage than the widely spaced threads of a wood screw. However, there are ways to minimize this risk or re-establish threads (more on this later).

It is safe to cut a screw to length in non-structural applications, especially during a time-sensitive project. It might even be necessary if your project requires a custom-length screw outside of standard lengths.

Avoid cutting structural screws or lag bolts shorter, as this can reduce load-bearing capacity. A shorter screw means fewer threads to bite into the material and more weight distributed over a shorter span. “Cutting also generates heat, which can weaken a screw or bolt,” Ricalde says.

How To Cut a Screw

While the steps to cut a screw will vary depending on the tool, all steps begin and end the same. First, mark your cut line on the screw with a permanent marker. When finished cutting, use sandpaper or a file to smooth down any rough edges.

Here are some more things to keep in mind as you narrow down what method you’re going to use:

• Always wear protective glasses and gloves when cutting a screw, and hearing protection with power tools. If using a rotary tool, angle grinder or oscillating saw, work away from open flames or flammable products, as these tools can generate sparks.
• Use a vise or pliers to hold a screw in place when cutting. This is safer and ensures an accurate cut. “If I’m cutting a tiny screw, I’ll use pliers to hold it,” Ricalde says, “Something larger, I’ll put it in a vise, so it doesn’t move.”
• Always cut screws using blades intended to cut metal. Bernacki likes Diebold carbide blades.
• Before cutting a machine screw, Ricalde suggests twisting a nut onto the screw above the cut line. “Then cut it where you want it and reverse it to get the threads right again,” he says.

With a rotary tool

For fast, accurate results, I like to use my rotary tool to cut screws to length. It’s Ricalde’s first choice as well.

With the tool at a high operating speed, press the cutting wheel into the screw at the cut line. Use enough pressure to keep the blade against the screw. Use two hands to hold the blade steady until cutting is complete.

With wire strippers

This method only works with machine screws. Wire strippers often have various-sized cutting holes for several common machine screw diameters. Thread the screw into the correct-sized cutting hole, then squeeze the hand grips closed until the screw is cut. “These provide a nice, clean cut every time,” Bernacki says.

With an oscillating saw

With the saw running, bring the blade to the screw. Hold the tool with both hands to maintain control, as oscillating tools can skip side to side when cutting. Keep light pressure, allowing the blade to do the work. Maintain contact between the screw and the blade until cutting is complete.

With a reciprocating saw

Depress the trigger on the saw to initiate blade movement. Apply moderate pressure to the tool while cutting, letting the blade’s back-and-forth motion do most of the work.

With a hacksaw

Place the blade against the screw at the marked line and move the saw back and forth while applying pressure. Continue this motion until the screw is cut.

With bolt cutters

Place the screw between the bolt cutter blades at the cut line. Squeeze the tool hand grips together with increasing pressure until the screw is cut.

With cutting pliers

Place the screw between the tool blades at the cut line. Squeeze the tool handles together, applying increasing pressure until the screw is cut.

With an angle grinder

Turn on the tool, then apply light pressure against the screw with the blade until the cutting is complete.

How to cut a screw sticking out of wood

Sometimes cutting is the only way to remove a screw that is bent or stripped and partially screwed into a surface. I like to use an oscillating tool, or multi-tool, in this scenario because it cuts the screw flush with the wood. “The nice thing about a multi tool is it doesn’t mar the wood when you’re making a cut,” Bernacki says.

Follow the steps for cutting a screw with an oscillating tool above, but keep the blade as close to the wood as possible.

FAQ

Is it safe to cut a screw shorter?

Whether or not cutting a screw shorter is safe really depends. Cutting structural screws and lag bolts can reduce load capacity, so it should be avoided. Outside of structural applications, it is safe to cut a screw shorter.

What tools can cut through a screw?

Use bolt cutters, wire strippers, cutting pliers, oscillating saws, rotary tools, hack saws, reciprocating saws or angle grinders to cut a screw.

Can you cut a screw without tools?

You will need some sort of tool to cut a screw. Non-powered tools used to cut screws include wire strippers, bolt cutters, cutting pliers and a hacksaw.

About the Experts

• Paul Ricalde creates home improvement videos on his YouTube channel, Paul’s Toolbox with over 360,000 subscribers. He has over thirty years of experience in the construction industry.
• Chris Bernacki owns WnC Home Improvement in Holyoke, Massachusetts. He brings more than 30 years of experience in the trades, renovating and remodeling commercial and residential properties.

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