Best Bolt Cutters - Types, Size Guide, How to Use & Adjust

Bolt cutters are essential tools for cutting and removing bolts, chains, padlocks, and other metal hardware. With the variety of bolt cutters available, it can be challenging to determine which is the best bolt cutter for your needs. This collection of Tonix Tools provides an in-depth look at how to select and use bolt cutters to handle tough metal cutting jobs.

With over 10 years of experience as a professional contractor, We've tested and used dozens of bolt cutters. My expertise is focused on providing recommendations based on real-world performance to help you choose the right bolt cutter.

What is a Bolt Cutter?

A bolt cutter is a hand tool used for cutting chains, padlocks, bolts, and wire. It consists of two pivoting blades with handles. The blades are brought together in a scissor-like motion to cut through metal hardware using the force generated by the compound lever action of the handles.

Bolt cutters utilize mechanical advantage to multiply the amount of force applied by the user, allowing the cutting blades to slice through tough materials like hardened steel. They are an essential tool for cutting locks, chains, bolts, and wire in various industries including construction, fire and rescue, law enforcement, and more. The size of the jaw opening determines the thickness of material the bolt cutter can cut.

How do Bolt Cutters Work?

Bolt cutters work on the principle of leverage, similar to a seesaw or a crowbar. Here's the breakdown:

1. Compound Hinge: The two handles of the bolt cutters are connected by a compound hinge. This hinge is designed to multiply the force you apply to the handles.
2. Leverage: As you squeeze the handles together, the hinge amplifies the force, transferring it to the blades.
3. Blades: The blades are short and incredibly strong. The concentrated force from the handles allows the blades to cut through thick metal with relative ease.
4. Cutting Action: Bolt cutters don't actually slice through metal like scissors. Instead, they exert so much force on a small area that they crush or shear the material.

Think of it like this: Imagine trying to break a pencil with your bare hands. It's difficult, right? But if you use a nutcracker (which also uses leverage), it's much easier because the tool concentrates your force onto a specific point.

The same principle applies to bolt cutters. The long handles allow you to generate significant force, and the hinge multiplies that force, making it possible to cut through materials that would otherwise be impossible to tackle.

Key Takeaway: Bolt cutters are essentially powerful levers designed to concentrate force and cut through tough materials quickly and efficiently.

Types of Bolt Cutters

Bolt cutters come in various types, each designed for specific applications and materials:

Standard Bolt Cutters:

• Purpose: General-purpose cutting of bolts, padlocks, chains, and other common metals.
• Blades: Center-cut blades, angled slightly inward for maximum cutting power.
• Ideal for: DIY projects, home repairs, and light-duty professional use.

Rebar Cutters:

• Purpose: Cutting through thick, hardened steel rebar used in construction.
• Blades: Extra-strong, hardened steel blades with a larger cutting edge.
• Handles: Longer handles for increased leverage to tackle tough materials.
• Ideal for: Construction sites, demolition projects, and heavy-duty metalworking.

Chain Cutters:

• Purpose: Specifically designed for cutting through chains quickly and efficiently.
• Blades: Specialized jaws with a curved profile for gripping and severing chain links.
• Ideal for: Cutting security chains, bicycle locks, and other chained objects.

Angle Cut Bolt Cutters:

• Purpose: Cutting in tight spaces or at awkward angles.
• Head: Angled at 25-30 degrees to provide better access in confined areas.
• Ideal for: Plumbing, electrical work, and any job requiring precision cutting in tight spots.

Clipper Cut Bolt Cutters:

• Purpose: Cutting flush against a flat surface.
• Blades: One flat side allows for clean cuts against walls, floors, or other flat surfaces.
• Ideal for: Cutting bolts or nails flush with the surface, removing padlocks, and demolition work.

A Bolt Cutter Size Guide: Finding the Right Fit for Your Needs

Choosing the right size bolt cutter is crucial for optimal performance and safety. Here's a comprehensive guide to help you find the perfect fit:

Bolt Cutter Sizing:

Bolt cutters are typically sized by the length of their handles, which directly correlates to their cutting capacity and leverage:

Material and Hardness:

Keep in mind that the cutting capacity also depends on the material's hardness. Softer metals like aluminum or copper are easier to cut than hardened steel. Always refer to the manufacturer's specifications for the maximum cutting capacity of a specific bolt cutter.

Choosing Your Size:

1. Assess Your Needs: Determine the types of materials and thicknesses you'll be cutting most often.
2. Consider Leverage: Longer handles provide more leverage but may be less maneuverable in tight spaces.
3. Prioritize Safety: Always choose a bolt cutter capable of handling the material you're cutting to avoid damaging the tool or causing injury.

How to Use Bolt Cutters

Bolt cutters are powerful tools that can make quick work of tough materials, but using them correctly is essential for safety and effectiveness. Follow these steps to get the best results:

1. Prepare and Inspect:

• Choose the Right Size: Ensure your bolt cutters are appropriately sized for the material you're cutting. Refer to the manufacturer's specifications and the bolt cutter size guide for guidance.
• Check for Damage: Inspect the blades and handles for any cracks, chips, or loose parts. Do not use damaged bolt cutters.
• Lubricate: If necessary, apply a few drops of oil to the hinge and blades for smoother operation.
• Wear Safety Gear: Put on safety glasses and gloves to protect your eyes and hands from flying debris.

2. Position the Material:

• Securely Support the Material: Place the material to be cut on a stable surface or use a vice to hold it in place. This prevents the material from moving or slipping during cutting.
• Align the Blades: Position the blades of the bolt cutter around the material, ensuring they're perpendicular to the cutting surface.

3. Cut with Confidence:

• Grip Firmly: Hold the handles of the bolt cutter with a firm, two-handed grip.
• Apply Steady Pressure: Squeeze the handles together slowly and steadily. Avoid jerking or twisting motions, as this can damage the blades or cause the material to slip.
• Let the Tool Do the Work: The leverage of the bolt cutter will do most of the cutting. Don't force it; let the blades gradually cut through the material.
• Repeat if Necessary: For thicker materials, you may need to reposition the cutter slightly and make multiple cuts.

4. After Cutting:

• Release Pressure: Once the material is cut, slowly release the pressure on the handles.
• Clean and Store: Wipe off any debris from the bolt cutter and store it in a dry place to prevent rust.

Tips for Using Bolt Cutters:

• Don't Overextend: Don't try to cut material thicker than the cutter's maximum capacity.
• Cut at a 90-Degree Angle: This ensures a clean, efficient cut.
• Use Both Hands: Always use both hands for maximum control and safety.
• Watch Your Fingers: Keep your fingers clear of the blades and cutting area.
• Don't Twist: Twisting the bolt cutters can damage the blades.
• Regular Maintenance: Keep your bolt cutters clean, lubricated, and properly adjusted for optimal performance.

How to Adjust Bolt Cutters

Over time, bolt cutters may become misaligned or develop gaps between the blades, hindering their cutting efficiency. Thankfully, adjusting them is a simple process. Here's how:

Tools You'll Need:

• Wrenches (usually two sizes: one for the jaw bolts and another for the adjustment bolt)
• A piece of paper or cardboard (optional)

Step-by-Step Guide:

1. Loosen the Jaw Bolts:

• Locate the two bolts on the side of the cutter head that hold the blades together.
• Use a wrench to loosen these bolts slightly, but don't remove them completely.

2. Align the Blades:

• Gently tap the blades with a hammer or mallet until they are perfectly aligned.
• Ensure the cutting edges meet evenly and there are no gaps or overlaps.

3. Tighten the Jaw Bolts:

• While holding the blades aligned, tighten the jaw bolts securely.
• Don't overtighten, as this can hinder the cutter's movement.

4. Adjust the Center Bolt (Optional):

• If there is a gap between the blades when closed, locate the center bolt near the handles.
• Turn the center bolt clockwise to close the gap slightly.
• Test the cutting action to ensure the blades meet correctly.
• You can use a piece of paper or cardboard to check if the blades are aligned properly. If the paper is gripped firmly when the cutter is closed, the adjustment is correct.

Important Tips:

• Always wear safety glasses and gloves while adjusting bolt cutters.
• Make small adjustments and test the cutting action frequently to avoid overtightening or misalignment.
• If the blades are severely damaged or worn, sharpening or replacement may be necessary.

FAQs

What's the difference between bolt cutters and wire cutters?

Bolt cutters are designed for cutting thick metal, while wire cutters are intended for thinner wires and cables.

Can bolt cutters cut through hardened steel?

Some heavy-duty bolt cutters are designed to cut through hardened steel, but standard cutters may struggle.

How do I sharpen bolt cutter blades?

Sharpening bolt cutter blades requires specialized tools and expertise. It's often best to leave it to a professional.

Are bolt cutters dangerous?

Like any tool, bolt cutters can be dangerous if not used properly. Follow safety guidelines to prevent injuries.