Best Way To Cut Exhaust Pipe – Step-By-Step Tutorials

If you’re working on a vehicle project that requires modifications to the exhaust system, one of the most challenging tasks is cutting the exhaust pipe.

Choosing the best way to cut exhaust pipe can make all the difference in the success of your project.

The right cutting method can ensure a clean cut, reduce the risk of damage to the pipe or surrounding components, and save you time and effort.

Let us walk you through some of the most common methods so you can choose the one that’s right for your needs.

Why Do You Need To Cut Exhaust Pipe?

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Cut Exhaust Pipe

Here are a few reasons you might need to make cuts through exhaust pipes.

  • Replace a damaged section: Over time, exhaust pipes can break down due to corrosion or impact damage. If it is severe enough, you might need to cut off the damaged portion and replace it with a new segment.
  • Install an aftermarket exhaust: Many car enthusiasts choose to install aftermarket exhaust systems to improve sound or performance. Installing a new exhaust often requires cutting the old exhaust system to remove it and make way for the new one.
  • Modify the exhaust system: The pipes may need to be cut and repositioned if you want to modify the exhaust system’s placement or direction. This is also the way to go when you want a louder exhaust system.
  • Repair a leak: Cutting off the damaged part of the exhaust system and replacing it with a new section is frequently a more affordable solution to the problem of a leak at the exhaust pipe.

In each of these scenarios, it’s crucial to carefully and precisely cut the exhaust pipe to provide a good fit and a secure and reliable repair or modification.

Suppose you are unsure about your ability to cut the exhaust pipe yourself; it is advised to seek help from a qualified mechanic or fabricator.

What Is The Best Way To Cut Exhaust Pipe?

Cutting the exhaust pipe can become tiresome and disorganized when you use the wrong tools. You can do this task easily with the help of pliers, a hacksaw, sawzall, air angle grinder, or a dremel.

Below are the best exhaust cutting tools that you can use to perform this task and how to use them.

With Pliers

Step 1: Ensure the exhaust pipe is clean, dry, and free of any dirt or debris. Gloves are necessary to protect your hands from cutting edges.

Step 2: Position the exhaust pipe in a vise or clamp to secure it in place. If you don’t have a vise or clamp, you can hold the pipe steady with your non-dominant hand.

Step 3: Mark the location of the cut on the exhaust pipe using chalk or a marker. To ensure a uniform pipe cut, make sure the mark is straight and level.

Step 4: Place the jaws of the pliers at the marked point. Make sure the pliers are tightly gripping the pipe.

Step 5: Squeeze the handles of the exhaust pipe cutter pliers with your dominant hand to exert pressure on the pipe. Continue to squeeze the pliers until they cut through the pipe.

Step 6: Verify the cut to make sure it is even and straight. If it isn’t, smooth away any jagged edges using a file or piece of sandpaper. And the work is done!

Note: Here’s how to cut exhaust pipe without saw. Using these exhaust pipe cutter pliers might not always be the perfect method for the job, particularly if the pipe is too thick or the cut calls for precision.

With A Hacksaw

Step 1: Put the hacksaw in the designated spot, making sure the pipe is directly in contact with the blade’s sharp edge.

Step 2: Press down on the pipe and firmly move the hacksaw blade back and forth across it.

The tubing must not be damaged, or you must not be injured for the saw blade to pass through it without enough pressure.

You will need patience to complete this because it is difficult and time-consuming.

Step 3: Halt once the blade reaches the hollow of the pipe. Remove the saw, flip the tubing over, and perform step 2 once again till you have finished cutting.

With A Sawzall

Step 1: Fit the saw with the appropriate blade and make the necessary setting adjustments to increase control and precision.

Step 2: Put the blade where it has been marked. Move slowly and steadily to prevent burning the pipe or the blade.

Suppose you are having problems cutting through the pipe; try using greater pressure or modifying the speed. After finishing the cut, let go of the trigger to remove the blade.

With An Air Angle Grinder

Step 1: Choose your cutting wheel selection and secure it to the grinder machine. Get your pipe ready for cutting.

Step 2: Turn on the grinder, then make the cut by bringing your hand at a 90-degree angle to the pipe. To avoid harming the tubing or the machine, apply just enough pressure to make a clean cut without going overboard.

Step 3: Reduce the pressure being applied slightly as the cut nears completion to avoid the saw’s backlash when it is finished cutting.

Note: There are numerous safety considerations to take when using the angle hand grinder.

To avoid problems when using this automotive specialty tool, make sure you read the instruction manual and adhere to all safety precautions.

With A Dremel

Step 1: Your work surface can be secured to the pipe using a bench vice. When the pipe is connected to a vehicle, it is fine to skip this step.

Step 2: The Dremel should be fitted with a cutting bit after making the necessary adjustments.

Step 3: Turn the tool on, then slide the cutting disc slowly over the tubing while applying sufficient pressure to make a cut.

Step 4: Smooth up the sharp edges using a grinding stone or metal file once you finish cutting.

Note: Due to the sparks produced by a Dremel, employ extra caution while cutting metal tubing to prevent scorching the metal and warping.

Also, make sure you work in an area with good ventilation, ideally outside, away from combustible materials or heat sources.

Other Tools To Cut Exhaust Pipe

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Other Tools To Cut

The most crucial step in cutting through an exhaust pipe is selecting the appropriate cutoff tool. Besides the ones mentioned above, here are some more options of the best tool to cut exhaust pipe.

Chop Saw

Chop saws are designed to sever huge pieces of metal or wood. Ensure that the chop saw blade you are using can cut through metal.

It’s probably the quickest method for cutting through an automobile’s exhaust pipe.

The negative is that it creates hot metal pieces that flak from the tub at a rapid pace, which might injure people.

Pipe Cutter

This hand chain cutter tool safely cuts through the exhaust tubing’s wall without spitting out hot metal shavings.

Suppose you do not have access to a power source or are far from your shop; this is an excellent solution.

It’s a satisfying technique to get a beautifully clean cut, too. Although it requires more time than any approach involving power tools, it nevertheless accomplishes the task.

Plasma/ Bolt Cutter

A plasma cutter is a strong cutting device that melts metal precisely by superheating it using an electrical arc.

Although it is a specialist and pricey tool, it might not be required for the majority of exhaust pipe-cutting activities.

Or, you can also use bolt cutters for cutting through thin sections of the exhaust pipe, although they may leave rough edges and distort the shape of the pipe.

Tips To Make Your Cutting Easier

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Tips To Cutting Exhaust Pipe Easier

Cutting exhaust pipe might be difficult, especially if you’ve never worked with metal before. Here are some tips to help with the process.

Prepare Tools

Don’t cut the pipe without taking all necessary safety measures.

Use protective glasses to shield your eyes from the tiny metal fragments that frequently fly into the air when cutting through the pipe. Moreover, you’ll be protected from stray sparks.

In case you are using a loud saw or the saw you use makes a screeching sound when it strikes metal, it is advised to wear ear protection.

Furthermore, check garments for dangling fabric or loose sleeves that could be caught in the saw blade.

Also, always wear metal work-rated gloves while working to protect yourself from unwanted cuts.

Take Measurement

If you need to cut off a portion of the pipe, measuring things can make your job much easier. Doing so multiple times to ensure accuracy.

You don’t want to be in a tight spot, as making a second cut to further reduce the pipe’s length is less concerning but still inconvenient.

Mark The Cut

Depending on the intended use, you should carefully examine where to cut exhaust pipe. When the time comes for the subsequent process step, make sure to provide enough room to produce welds.

Secure Your Pipe

Once you make the cut, lock the pipe securely using a bench vice to prevent it from moving. This way, your pipe will stay perfectly still, so you can cut it more easily.

Also, keep in mind to spare about three inches between the cutting area and the vice jaw’s end so you can avoid running into the vice with the saw while working.

Frequently Asked Questions

Does Cutting My Exhaust Pipe Make It Louder?

Yes. Still, how loud it will turn out depends on how and where you cut muffler pipe. The exhaust note will sound louder when you make a cut close to the engine.

Also, removing a muffler or resonator, which is intended to lower the exhaust volume, may result in a louder exhaust.

How Much Does It Cost To Hire A Professional To Cut My Pipe?

For an expert to cut the exhaust pipe on your car, you should budget from 50 to 150 dollars.

This cost may include additional services such as welding, but this will depend on the specific service provider and the job’s complexity.

Can I Cut The Muffler Off?

Yes. Emissions and engine performance are controlled by the car’s exhaust system up to the muffler. The sole purpose of the muffler is to block out engine noise as it is increased by the pipe.

So long as you don’t experience any power reduction or other significant problems, you should be free to remove the muffler.

The Bottom Line

So there you have our list of the best way to cut exhaust pipe.

Whether you choose a cutting wheel, a reciprocating saw, or a specialized pipe cutter, it’s essential to take the time to prepare properly and choose the right method for your specific needs.

Keep in mind that safety should always be a top priority when working with power tools, and wearing the right protective gear is crucial.

By following these tips and techniques, you can cut your exhaust pipe with confidence and achieve the results you’re looking for.

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