How to Cut a Metal Bar for a Filing Cabinet

Cutting metal bars for a filing cabinet requires some specialized tools and safety precautions. With the right approach, you can make clean, precise cuts to create a customized filing system.

Gather the Necessary Materials

You will need:

• Metal bars – stainless steel or aluminum work best for filing cabinets. Make sure the bars are the desired width and thickness for your cabinet.
• A hacksaw with a blade suitable for cutting metal. A fine-toothed blade will provide the cleanest cuts.
• A miter box to guide straight cuts across the bars.
• A metal file to smooth cut edges. Look for a bastard or second cut file.
• Sandpaper in varying grits to further smooth and polish cut edges.
• Safety glasses and work gloves for eye and hand protection.
• A vise or clamps to securely hold the bars while cutting.

Measure and Mark Cut Lines

First, measure the length you need for each bar and mark the cutting line clearly with a permanent marker.

Allow an extra 1/4 to 1/2 inch beyond your finished size to account for the blade kerf and squaring off the ends.

Use a combination square, protractor, or miter box to mark 90 degree cut lines across the bar for a precise fit.

Secure the Bar Properly

Clamp your metal bar horizontally across the miter box or secure it vertically in a sturdy vise.

Make sure it is held tightly and cannot vibrate or twist during cutting.

Wear safety glasses and work gloves for protection.

Cut the Bar Slowly and Evenly

Place your hacksaw blade into the miter slot or against the marked cut line if using a vise.

Keep the blade perpendicular to the bar.

Applying steady pressure, begin cutting using the full length of the hacksaw blade.

Let the hacksaw do the work – don’t force or bend the blade.

Periodically tighten the hacksaw frame.

Maintain an even pace without twisting the blade. Cutting too quickly can bend the blade or leave jagged edges.

File and Sand the Cut Ends

Once cut, use a metal file to smooth any rough edges and create a flat, straight edge. File at an angle perpendicular to the cut edge.

Progress through varying grits of sandpaper to further refine the edge. Wrap sandpaper around a wood block for best grip.

Finish by wiping away any metal residue with a soft cloth. Clean, smooth edges will ensure safe installation.

Safety Tips

• Wear eye and hand protection at all times when cutting metal.
• Make sure the bar is completely secure before starting any cuts.
• Pay close attention to the blade during the cut and maintain control.
• File and sand edges in the same direction to prevent scratches.
• Take your time and don’t rush any steps. Smooth, clean results require patience.

With the proper preparation and tools, cutting metal bars for a filing cabinet is a manageable task for a devoted DIYer. Just remember to prioritize safety and precision in equal measure. Taking a careful, methodical approach will deliver professional-grade cuts every time.

Frequently Asked Questions

What type of blade should I use to cut metal bars?

For cutting metal bars and tubing, use a fine-toothed hacksaw blade – 18 or 32 teeth per inch is ideal. This will provide a smooth cut with minimal metal shavings.

Can I cut thick metal bars with a hacksaw?

Yes, hacksaws can cut metal bars up to 1/4 inch thick, though it requires patience and muscle. For thicker bars, use a power miter saw with a metal cutting blade or turn to an angle grinder.

What is the best way to cut a straight line across a metal bar?

For straight cuts, take advantage of a miter box guide. Rest the metal bar in the miter box grooves to keep the hacksaw blade perfectly perpendicular as you cut.

Should I lubricate the hacksaw blade before cutting?

No oil or lubricant is needed for cutting metal with a hacksaw. The friction helps clear away metal shavings. Simply tighten the blade periodically as you cut.

How can I stop the cut ends of metal bars from being sharp and jagged?

Use a bastard file followed by increasingly finer grit sandpaper to smooth and round over the cut edges. Wipe away any metal residue when finished polishing the edges.

Conclusion

Cutting metal bars for a custom filing cabinet takes the right tools and a careful approach, but it is an achievable task for a committed DIYer. By following standard safety precautions, marking cut lines precisely, securing the bar properly, sawing evenly, and smoothing the edges, you can achieve clean, professional results. Patience and letting the tools do the work will be rewarded with precisely fitted bars ready for assembly. Just take it slow and don’t force the blade – precision will triumph over speed.