Best metal cutting chop saws

Best chop saw (Abrasive wheel for metal studs)

Smaller 12-inch chop saw

Alternative sized chop saw

Cordless chop saw

Chop saws are power tools that are used to cut through metal and other hard and dense materials. They look pretty much like standard drop saws, but they use abrasive cutting discs instead of toothed blades to do the cutting. 

Chop saws are especially capable of making straight and precise cuts in a variety of metal materials.

They are commonly used by carpenters, house framers, and metal workers to make square cuts. However, chop saws can only cut at 90° angles, so they can’t be used to make a variety of angled cuts like 45° bevels. 

For making angled cuts, most pros used a variant of the chop saw known as a metal cutting miter saw, or cold saw. 

These types of saws can handle a wider range of jobs than most basic chop saws and are especially useful for making angled cuts quickly and accurately. 

The abrasive discs used in chop saws do an excellent job of cutting through most materials like PVCs. They come with different types of abrasive material, each suited for specific tasks.

One thing that you have to consider, however, is that the abrasive discs used in chop saws are essentially disposable. The grinding action and the heat that they produce when they come into contact with the metal cause the abrasive coating to wear away quickly, preventing them from cutting metal effectively.

When this happens, you will have to replace the cutting disc. This is not the case with cold saws.

Features to think about first

• Electronic monitoring system. Monitors the number of rotations that the chop saw makes, ensuring consistent performance even under load. 
• Smooth start function. Reduces power drawn when the chop saw is turned on, preventing it from jerking.
• Brush replacement system. Facilitates the replacement of carbon brushes in the motor, helping prolong tool life.
• Belt drive. It protects the motor from overloading and reduces the risk of overheating.
  

Before you buy a chop saw…

1. Is it durable?

Chop saws are expected to handle heavy-duty jobs and cut through some hard materials.

Although the abrasive disks will have to be replaced periodically, the mechanism and components should be able to hold up to the demanding conditions they are subjected to.

Cold Saws should have blades fitted that can cut hard metal materials rather than blades made to cut timber.

2. Who makes the tool?

The best chop saws are made by companies such as DeWalt, Fein, Evolution, and Makita.

Tools from these manufacturers are notable for their build quality and attributes, as well as their ability to handle a wide variety of cutting tasks.

They tend to last longer than chop saws made by other manufacturers.

3. What’s the compatible blade size?

Bigger blade sizes allow you to make deeper cuts into the material, which is useful for cutting thicker metal.

Larger blades spin at slower speeds than small blades, so they produce fewer sparks than faster-spinning small blades.

4. What’s the blade type?

Tungsten blades last a lot longer than abrasive wheels.

They can cut much more material before wearing down and needing to be replaced, so you save a lot of money on replacement blades.

Although many chop saws still utilize abrasive discs, tungsten-tipped blades have pretty much taken over the pro-market.

5. Is it light enough weight to move around?

Chop saws should be heavy enough that they allow you to make cuts with sufficient pressure but not so heavy that they are difficult to move.

Chop saws for the industrial market can weigh as much as 100 pounds or more. Models intended for personal use are considerably lighter, weighing in at around 40 pounds or less.

6. Is it worth the price?

Chop saws can be quite expensive, but that doesn’t mean you should go for the cheapest model you can find.

Spending more on a quality model from the brands mentioned above will assure you of a well-built tool that will handle even demanding jobs and last a long time.

The main difference between cold saws and chop saws is that the latter uses toothed steel blades, while the chop saw uses abrasive wheels.

Some cold saws use coolant fluid to transfer heat from the metal to the filings produced by the cutting process.

The metal getting cut, therefore, remains relatively cool or in a “cold state.”

In contrast, chop saws grind away at the metal, producing considerable amounts of heat while it cuts. 

Cold saws run at very low speeds compared to chop saws. In most cold saws, the blade spins around 1300 RPM. Chop saws typically run up to 4,000 RPMs or faster.

Interestingly enough, cold saws running at slower speeds will cut metal more efficiently than a chop saw spinning at 4,000 RPM or more.

Additionally, cold saws come in a wider range of RPM speeds and have more tooth options available with their blades.

In addition, they make cleaner, burr-free cuts than chop saws, eliminating the need for deburring after cutting.

Metal cutting saws come in a range of blade sizes, from 5⅜” up to 20”. There are even larger blades for industrial applications.

For DIY and most Trade metalworking, however, the blades used are smaller, with the most common sizes being 12”. DeWalt makes a range of excellent metal cutting saws, with blade sizes for 6”, 12”, 14”, and 15”.

Combined with the smaller blades, metal cutting saws spin at slower RPM speeds than the standard circular saws used for framing work.

Cold saws use toothed blades to cut metal, transferring the heat from the blade and workpiece to the chips and metal filings.

The workpiece and the blade, therefore, remain relatively cool, which preserves the life of the blade and helps in immediate handling of the workpiece. 

Chop saws, on the other hand, use abrasive discs made of composite materials that grind through the metal with friction.

This process produces a great deal of heat in the material and discs, which causes the discs to wear out pretty quickly.

For serious metalwork, however, or if you have repetitive cuts through a wide variety of metal like steel framing, it is always better to go with a cold saw or a chop saw as you will save a lot of time.

Or at least an AC-powered Makita or DIY Craftsman angle grinder.

Angle grinder disks don’t last that long for repetitive cuts, and the cost of replacement adds up. Same with chops although the blade won’t need to be changed nearly as often due to a slightly thicker, and much bigger blade.

Cold saws, however, have a blade that will not wear out quickly as abrasive wheels do.

DeWalt and Fein make some of the finest chop saws on the market.

DeWalt’s are popular choices due to their durable build quality and their bright yellow design.

Although cheaper than most cold-cut saws, DeWalt chop saws provide adequate power and performance for most cutting jobs.

Amazingly, they come with a host of useful attributes such as “quick-lock” vises for quick and easy clamping and releasing of workpieces.

Fein is known mostly for its quality cold saws, one example of which is the 14” Slugger.

The build quality of its tools is generally pretty impressive, and they likewise come with attributes such as chip trays and blade guards, all of which can be useful for pros and DIYers alike. 

Fein saws are a bit more expensive than DeWalt’s and most other brands of chop saws, for that matter.

But if the quality is what you are looking for in a chop saw, Fein will definitely deliver.

For sheer value for money, you can’t beat the DeWalt D28730. A 14” model driven by a powerful 15-amp motor, it delivers impressive performance with no risk of overheating.

Get better control with its ergonomic “D” handle that reduces hand fatigue, allowing you to work for hours without discomfort.

The D2872 takes pride in its Quick-Lock vise that lets you secure workpieces quickly and easily, so you won’t have to worry about wobbling or misalignment.

Moreover, you get built-in overload protection and a 45° pivoting fence that lets you make a variety of angle cuts. 

The DeWalt DW872 ticks all the boxes when it comes to metal-cutting saws. The 14” carbide-tipped cold saw blade cuts through a surprising variety of metals, even 5”  pipe and 3” solid bar stock.

If you have to cut through struts, threaded rods, angle iron, and rebar, this one will do the job without issues.

The DW872 does most of these tasks with ease, cutting through metals much faster than most any other saw.

Additionally, you get a nice clean finish with your cuts, eliminating the need to touch up, grind, or fill in the cut edges afterward. 

The Evolution EVOSAW380 is an absolute beast of a chop saw, pumping out 1800 watts of power.

The 15 amp motor, coupled with a high torque gearbox, drives a 15” blade that can cut through a variety of steel and metal materials, leaving a smooth and burr-free edge.

The EVOSAW380 is a cold-cutting saw that requires no coolant to keep the workpiece cool.

It doesn’t produce any sparks either, and the blade is good for more than 1,000 cuts before you even have to think about looking for a replacement.

If you are looking for industrial performance in a reasonably-priced chop saw, the Evolution EVOSAW380 is the only real choice.

You can use chop saws to cut several steel studs at a time.

With a high-quality chop saw, you could even cut up to ten steel studs in one go. However, chop saws tend to leave sharp burrs on the cut edge of the metal.

It will, therefore, require an extra step to smoothen out these burrs if you want a smooth edge with a metal file. 

One option is to use a pair of tin snips or; metal scissors that won’t leave burrs on the metal cut. The main drawback of tin snips is that they can only cut one piece at a time.

It will, therefore, take you much longer to cut metal studs in large batches with tin snips as compared to cutting an entire batch with a chop saw or cold saw.  

If you do decide to use tin snips, the best tool for the job is a pair of straight-cut aviation snips.

Chop saws are so powerful that they are mostly used by engineers and carpenters. They can cut through even large and thick pieces of metal fast, making them excellent choices for metalworking and construction.

On many building sites, you will typically see chop saws used for making frames for houses or cutting through steel reinforcement bars. 

Of course, chop saws can be useful for DIYers, particularly those that need powerful metal-cutting tools for heavy-duty jobs.

There are many corded models that are easier to use than hydraulics-powered chop saws.

If you frequently have to cut through steel studs or bars, a chop saw can be set up on a workbench to cut metal more easily than by freehand with an angle grinder.

Besides,  you can cut galvanized pipes with a chop saw and other tools listed in this blog.

If you need to cut curves or circles in metal, check this guide out.

The best metal-cutting cold saws have heavy-duty aluminum catchers that catch the swarf or fine metal filings produced by the blade during cutting.

They can make clean and precise cuts without burrs, so there is usually no need to smoothen out the edges afterward. You won’t have to wait for the metal to cool down after cutting as you would with abrasive saws.

And you can cut any type of metal beam as long as you can lift it onto your bench.

Most people wouldn’t necessarily turn to a miter saw when they need to cut metal.

But they can actually do a pretty good job of cutting aluminum and even steel, provided you fit them with a fine-toothed blade. 

In addition to a high teeth count, you should go for a blade that provides a triple-chip grinding action, which results in clean, burr-free edges.

You will get better results with composite blades made from aluminum oxide, which can be quite effective for cutting steel and aluminum bars.

Keep in mind that miter saws are better suited for one-offs and small batches of metal.

The blades spin much faster than standard metal-cutting saws.

So the heat that they produce makes them less suitable for cutting big batches of metal sheets or stock.

And you want to save the wear and tear of metal cutting jobs away from your miter saw used for precision finishing jobs.

1. Learn the proper positioning.

As with all power tools, proper positioning is essential for using your chop saw safely.

You will want to set your workbench at around waist height or just slightly lower to give you enough leverage to control the saw and operate it comfortably, rather than just using it on the ground like the worker above. 

2. Make a protective barrier against the wall. 

Sparks are always a concern when working with cutting or grinding power tools.

The cutting and grinding action of the wheels produces tiny shards of metal which are typically sharp and hot.

Over time, these particles could leave unsightly marks on the wall. To prevent this from happening, place a sheet of plywood against the wall behind the saw to serve as a protective barrier. 

3. Wear protective gear. 

Of course, you will want to protect yourself from these sparks as well. Always wear safety glasses when working with a chop saw, or better yet, use a full face shield.

You might want to cover your hands and arms with appropriate gloves and a long-sleeved shirt made of flame-retardant material. 

You will generally want to wear gloves anyway, as cut metal could have sharp edges.

Always let freshly cut metal cool down sufficiently before handling it to keep from singeing yourself. 

4. Finally, make sure that no one gets too close while you are working.

If someone you are working with must be close by, make sure that they are wearing protective equipment as well like ear protection and eye protection.

If you want to get more for your money, you can’t do better than the DeWalt D2872 cold saw. It cuts with a 14” blade powered by a 15 amp motor, giving you sufficient cutting power for most jobs.

Moreover, it does angle cuts thanks to its 45° pivoting fence. It handles these jobs with a constant running speed with no sparks as well, with little need for de-burring afterward.

Finally, check out the Evolution EVOSAW380 for an industrial-strength chop saw/cold saw in a convenient DIY-friendly package.

The cold-cutting action helps in quick work, and you get smooth and burr-free edges as well.

Dewalt D28730