How to Cut Very Thick Wire Safely

For very thick wire, start with a bolt cutter whose jaw opening and stated cutting capacity accommodate the wire’s diameter and material; a cutter that barely fits around the wire may not be rated to cut it. Our Heavy-Duty Bolt Cutter – 8in to 24in | Precision Lock & Wire Cutting Tool comes in several lengths, but length alone does not tell you whether a particular cutter can handle your wire, especially if the wire is hardened.

Check the product’s listed specifications when evaluating choose the right cutter for the wire.

Put on eye protection and sturdy gloves, then secure the wire so the cut end cannot spring toward you or someone nearby; if the wire is under tension, release that tension before cutting. If it could carry electricity, shut off the power and verify it is de-energized with an appropriate tester before touching it, and leave utility lines or any wire you cannot positively identify to a qualified professional.

Place the wire as deep in the bolt cutter’s jaws as the tool allows, keep the cutter square to the wire, and close the handles with controlled, even pressure. Keep your fingers away from the jaws and the cut end, and do not twist the cutter, add a pipe to the handles, or force a cut that the tool cannot complete.

Check the product’s listed specifications when evaluating position the jaws and apply steady pressure.

For a cable made of many fine strands, a cable cutter may leave a cleaner end than a bolt cutter, while a thick solid wire may call for a bolt cutter rated for its size and material. If the jaws slip, the handles will not close, or the wire is harder than the cutter is rated for, stop and choose a suitable tool rather than risking damaged jaws or a sudden break; our bolt cutter sizing guide can help you compare tool sizes before you begin.

Expect a sharp edge, and handle or cap it as needed before the wire goes back into use or into storage. Wipe debris from the cutter, inspect the jaws for chips or misalignment, and store it dry so it is ready for the next job.