Even the most well-planned projects can have a small problem that could cost you in time, screws that are too long might not seem like much of an issue, but when they’re sticking out they can be a big problem.

Knowing how to cut screws can help you save time and hassle, whether you’re fixing hardware, installing furniture, or working in tight spaces.

Using the right tools is vital, and having the right technique can make all the difference, so here we share our guidance on how to cut screws, helping you to avoid the mistakes that are all too common in this area.

Why might you need to cut screws?

There are many scenarios where you might find yourself having to cut screws, they include:

Wrong length screws: You might only have longer screws available than the material depth you’re working with.
Preventing protrusion: Cutting a screw can help stop it from poking through the other side of a panel or surface.
Working in restricted spaces: Shorter screws might be needed if you’re working on tight cavities.
Reusing existing stock: Rather than buying new, it sometimes makes sense to modify what you already have and avoid waste.

What tools do you need to cut screws?

The great thing about cutting screws? Specialist equipment isn’t needed. However, the right tool can make the job a lot easier and more efficient. Here are the best options:

Hacksaw

Use a hacksaw for small jobs or one-off cuts. It’s a simple and inexpensive way to cut screws. What’s more, you have decent control. But be warned, if your screw is made from a harder metal, cutting can be slow and tiring.

Bolt cutters

Bolt cutters are ideal for cutting thicker screws or bolts. However, they can sometimes crush threads rather than slicing them cleanly, so you may need to apply some post-cut filling.

Dremel or rotary tool

A rotary tool that is fitted with a metal cutting disc is perfect for clean, precise cuts – especially when you have smaller screws or awkward locations.

Angle grinder

Angle grinders are powerful and fast, making it great for when you need to cut multiple screws quickly. This tool isn’t suited to delicate jobs or very small screws though.

Screw cutting pliers

Screw cutting pliers are designed to work on smaller machine screws and electrical screws. They’ll cut them cleanly and protect threads by keeping the screw in place as it’s cut.

Bench vice or clamp

Ok, so this isn’t a cutting tool, but they can be useful for keeping your screw firmly in place while you cut. A vice will keep your hands free and the screw stable.

Step-by-step guide: How to cut screws safely

Choose the right tool

Think about the screw material, size, and your working environment. For most DIY and trade jobs, a rotary tool or hacksaw will suffice for handling typical wood screws or machine screws.

Mark the cutting point

Use a pencil or marker to indicate exactly where you want to cut. Measure twice and cut once.

Secure the screw firmly

Always clamp the screw in a bench vice or locking pliers. This helps to stop it spinning or slipping as you cut.

Cut slowly and evenly

Apply steady, even pressure as you cut. Avoid forcing the tool, as this may heat the metal, which can lead to damaged threads.

Smooth and clean the cut end

Once cut, use a metal file or fine sandpaper to smooth sharp edges to help with installation, making it easier and safer.

Test the fit

Always check the trimmed screw in the intended location before installing it to ensure smooth threading.

Quick reference: Which tool to use to cut your screws

Tool	Best For	Caution
Hacksaw	Small, occasional cuts	Slow on hard metals
Bolt Cutters	Thicker screws/bolts	May deform threads
Dremel	Precision cuts	Requires a steady hand
Angle Grinder	Bulk cutting	Not for small screws
Screw Cutting Pliers	Electrical/machine screws	Limited to small sizes

Common screw materials and how they affect cutting

When you’re cutting screws, the material they’re made from has a big impact on whether it’s an easy or difficult task. This is how the screw material affects the cutting process:

Steel screws

Steel screws are used as they’re strong and durable. But obviously, when it comes to cutting they can be challenging. Using a hacksaw with a high-quality blade is best, but you’ll have to be patient and put plenty of effort into the cut. An angle grinder with a cutting disc will get you the cleanest cut.

Stainless steel screws

Stainless steel screws are designed to be strong and corrosion-resistant, which means cutting them is challenging. To cut them effectively, power tools are best. Additionally, use cutting lubricants to reduce heat buildup and extend the life of your tools.

Brass and aluminium screws

Brass and aluminium screws are softer and more malleable, which makes them relatively easy to cut. A standard hacksaw will get the job done with ease. When cutting brass, apply steady, consistent pressure to get a smooth cut. As aluminium is softer, it’s best to choose a blade with fewer teeth per inch, as it may clog up saw blades as it cuts so quickly.

Coated screws

Coated screws have an added layer of protection against corrosion. Cutting these screws can compromise this coating, which may lead to rust or corrosion over time. To help stop this, touch up the cut ends with sealants or paints to restore their protective barrier.

How to protect threads when cutting

If you need a clean cut and want your screws to thread smoothly afterwards, a few simple tricks can make all the difference. Here’s how to protect your threads when cutting screws:

Thread a nut first: Before you cut, run a nut onto the screw, past the point where you plan to cut. Once cut, back the nut off to straighten any threads that may have shifted or been slightly deformed. It’s an old-school trick that’s still used for a reason – it works.
Tape it up: Wrap a layer of masking tape around the threads near your cut line. This helps reduce burring (tiny, rough edges left after cutting metal) and keeps fine metal shavings from clinging to the threads. Once you’re done, peel the tape off for a cleaner result.
Cut long, then file: Leave your cut just a little longer than needed, then use a metal file to smooth and finish the end. This helps to stop sharp edges and ensures your thread is still working as it should.

Top safety tips when cutting screws

Wear safety goggles to protect your eyes from flying metal fragments.
Use gloves to protect your hands from sharp edges and heat.
Work in a clear, well-lit space with good ventilation.
Allow cut screws to cool before handling.
Keep your cutting tools well-maintained and sharp.

Can you still use the screw after cutting?

Yes, in most cases. As long as you cut carefully and clean the threads, screws should remain perfectly usable after being shortened.

However, if you damage the threads during cutting, it might be hard to insert or tighten the screw. Using a thread file or running a matching nut over the cut end can help restore clean threads.

Alternative solutions if cutting isn’t ideal

Sometimes it’s just not ideal to cut a screw. If this is the case, you could try:

Use shorter screws if they are available.
Add washers or spacers to take up the excess length.
Countersinking or pre-drilling deeper pilot holes where the material allows.

Choosing the right screw length from the start

Cutting screws is a handy trick, but let’s be honest, it’s even better if you don’t have to cut them at all. Here’s how to pick the right length from the start:

Measure twice, screw once: Start by adding up the material thickness and the depth of any pilot holes you’re drilling. This helps ensure the screw anchors securely without poking out the other side.
Don’t forget countersinking: If your project involves countersinking (where the screw head sits flush or slightly below the surface), remember to account for that extra depth. It’s a small detail that can make a big difference.
Check sizing charts: Manufacturers often give sizing guides or charts. It’s always worth looking at them, as they can save guesswork and help you match the screw length to the materials perfectly.
A simple rule of thumb: In general, aim for about two-thirds of the screw to embed in the base material, as you’ll have solid holding power without unnecessary length.

Mistakes to avoid when cutting screws

Rushing the cut and overheating the screw.
Not securing the screw properly before cutting.
Using the wrong cutting tool for the job.
Failing to smooth sharp edges after cutting.

By taking a little extra care, you can make all the difference to both safety and the finished result.

Learning how to cut screws is a valuable skill that may help you to get out of a tight spot on site or at home. With the right tools and techniques, it’s quick, safe, and gives you the flexibility to work with fixings of all types.

At ASP Ltd, we stock a wide range of screws, fixings and tools suitable for any project – whether you’re a tradesperson or home DIYer. If you need advice on choosing the right products, our team is always here to help.