How to Cut an Exhaust Pipe Without a Saw?

How to Cut an Exhaust Pipe Without a Saw?

Cutting an exhaust pipe without a saw can be a challenging task, but with some creativity and the right tools, it is possible. It is important to remember that safety is paramount when attempting this project and that you should always use proper protective gear. In this article we will discuss various methods for cutting an exhaust pipe without a saw as well as answer frequently asked questions about the process. With this knowledge, you can confidently tackle your project with great success!

Exhaust Pipe Function

Before beginning your project, it is important to understand the purpose of an exhaust pipe. The exhaust pipe serves as a channel for hazardous gasses produced by an internal combustion engine to be expelled from the vehicle. These gasses can include carbon monoxide, hydrocarbons, nitric oxides and other pollutants. By safely disposing of these fumes outside of the vehicle, it helps to protect the driver and passengers from inhaling dangerous pollutants. [1]

Exhaust Pipe Function

Chain Pipe Cutter or Tailpipe Cutter

Using a chain pipe cutter or tailpipe cutter is one of the best ways to cut an exhaust pipe without a saw. This tool is specifically designed for cutting exhaust pipes and can be easily operated with minimal effort. Chain pipe cutters feature a long metal blade that resembles a chain, while tailpipe cutters come with two sharp blades which are used to cut through the pipe.

To use a chain pipe cutter, simply slide the blade around the circumference of the exhaust pipe and then press down firmly to cut through it. This tool requires minimal effort since you don’t have to saw back and forth on the pipe. Additionally, it won’t create any sparks or mess like saws do, helping to keep your work area clean and safe.

Tailpipe cutters are also easy to use and come with built-in safety features that make them safer than saws. To use a tailpipe cutter, you simply need to line up the blades around the circumference of the pipe and then press down on the handles until they’re completely locked in place. [1]


One of the best ways to cut an exhaust pipe without a saw is to use a hacksaw. A hacksaw is a hand-powered saw that has teeth on one side and a handle on the other. It can be used for cutting through tough materials such as metals, plastic pipes, and even wood. The teeth on the blade are set in alternating directions so that they will cut on both the push and pull stroke.

When using a hacksaw to cut an exhaust pipe, be sure to use a suitable blade for the material you’re cutting. A bi-metal or carbon steel blade is usually best as it can handle the heat generated by cutting metal pipes. To make your cuts straight and even, clamp the pipe securely to a workbench and use a straight edge as a guide for your saw.

If you’re working in tight spaces, then an Oscillating Multi-Tool might be the better option. This is a power tool which uses oscillating motion to rapidly cut through materials like exhaust pipes or other metal objects in no time at all. [1]

Angle Grinder

An angle grinder is one of the most common tools used for cutting an exhaust pipe without a saw. It’s easy to use and can cut through metal quickly and easily, providing a clean edge in just a few seconds. The key when using an angle grinder is to take your time, wear protective gear like safety goggles and a face shield, and be sure to use the right kind of grinding wheel for your particular exhaust pipe material.

Once you have all the necessary safety gear and the correct grinding wheel, here’s how you can cut your exhaust pipe with an angle grinder:

  1. Secure your pipe in a vice and make sure it won’t move while you’re cutting it.
  2. Make a mark on the pipe where you want to make the cut.
  3. Place your angle grinder so that the grinding wheel is just barely touching the mark you made.
  4. Start up your angle grinder and carefully move it along the line, applying steady pressure until you’ve finished cutting through the metal.
  5. Let the grinder stop completely before removing it from the pipe. [2]

Angle Grinder

Homemade Exhaust Pipe Cutter

If you don’t have a saw or other type of cutting tool, you can use a homemade exhaust pipe cutter. This is the most basic way to cut an exhaust pipe without using any tools. To make your own homemade exhaust pipe cutter, all you need are two pieces of metal (preferably steel) that are strong enough to hold the shape while you cut.

First, you need to create two slots in each piece of metal. This should be wide enough for the exhaust pipe and tall enough so that it won’t slip while you are cutting. Make sure your cuts go all the way through both sides of the metal pieces.

Next, secure the two pieces together at one end with a strong bolt or screw. This will help create a solid base and prevent the pieces from slipping while you’re cutting. Now place them around the exhaust pipe where you want to make your cut and then tighten them up until they are firmly gripping the pipe.

Finally, use a hacksaw or similar tool to carefully cut through the metal and exhaust pipe together. [2]

Using Shears

If you’re looking for an alternative way to cut exhaust pipes without using a saw, then shears are the perfect tool. It can make quick work of any metal that comes its way, and it will leave a smooth edge. Shears are typically used on thin metals, such as those found in exhaust systems, as they can easily cut through them without much effort.

The best way to use shears is to start by marking the area you want to cut with a chalk or marker. Once marked, position the shears around the pipe and firmly squeeze together until you feel the metal come apart. Keep squeezing until you’ve completely separated the two pieces. [2]

Using Shears

Potential Problems

There are a few potential problems to consider when cutting an exhaust pipe without a saw. Firstly, you may end up with an uneven cut along the length of the pipe. This can be especially problematic if you’re trying to install a custom exhaust system and don’t want any gaps or irregularities in the line.You also need to be aware that this type of cut can be dangerous as it may cause the exhaust pipe to break or separate from its fittings.Finally, this method may not work on certain types of metal such as stainless steel, which require specialist tools and techniques for a proper cut. [2]

Pull Bar

The pull bar method is a great way to cut an exhaust pipe without using a saw. All you need is a pipe wrench, a pair of pliers, and some duct tape.

Start by positioning your pipe on the ground so that it’s level and secure. Wrap duct tape around the area where you want to make the cut. This will help to keep the pipe together while it’s being cut.

Next, place the pull bar between the two pieces of duct tape. Make sure that the pull bar is positioned in such a way that it won’t slip off during the cutting process. You can secure it with the pliers if necessary. [2]

Pull Bar

Using Multi-Tool

A multi-tool is a great alternative for cutting an exhaust pipe if you don’t have access to a saw. It has multiple features which make it ideal for this job, namely the sharp blades and the ability to be versatile in various tasks. To use the multi-tool to cut your exhaust pipe:

  1. First, mark where you want to make the cut on the exhaust pipe using a marker.
  2. Select the blade you need for cutting and insert it into the multi-tool handle. Make sure that the blade is firmly in place, and you can do this by tightening the screws on the side of the tool until they are secure.
  3. Place your multi-tool onto the marked line and start cutting. Make sure to keep the blade pressed firmly against the pipe, as this will ensure that you make an even cut.
  4. Once you have finished making the cut, it is important to inspect your work. Look for any rough edges or unevenness on the end of the pipe and use a file or sandpaper to smooth them out if necessary. [1]

Rubber Mallet

Using a rubber mallet is the first option to cut an exhaust pipe without a saw. Before you start, make sure to use protective gloves and safety glasses.

Start by using the mallet to mark the area of the pipe that you want to cut off. The aim is to create a dent in the pipe which will act as a guide for your cutting tool.

Once you’ve marked the area, use a cold chisel or flathead screwdriver to start making cuts in the pipe. Make sure that your cutting tool is at least as thick as the dent you made with the rubber mallet. Cut along the line of the dent until you reach the end of the pipe. If necessary, use a file to grind off any rough edges and make the cut as smooth as possible.

If you’re having trouble making straight cuts, try using a hacksaw blade instead of a cold chisel. Secure the blade in place with pliers and start sawing at the pipe with short strokes. It may take some time but it should eventually get through the metal. [1]

Drill or Spade Bit

If you’re looking for an alternative way to cut an exhaust pipe without a saw, consider using a drill or spade bit. This method involves drilling holes in the metal exhaust pipe and then prying it apart by hand or with pliers. First, you will need to make sure that your drill bit is the same size as the thickness of the exhaust pipe so that the hole is not too big. Then, start drilling along the line of your cut, making sure to keep the bit perpendicular to the pipe while you drill. Alternatively, you can also use a spade bit for this task. Once you have drilled several holes along the line of your cut, simply pry apart the sections with pliers or by hand and discard any excess metal.

This method is a great alternative if you don’t have access to a saw or want to avoid the sparks associated with cutting metal, but it can be time consuming and may require additional tools such as pliers.

Additionally, this technique won’t give you the precise cut that a saw would, so make sure your measurements are correct beforehand! [1]

Drill or Spade Bit

The Dremel Trio

The Dremel Trio is a great tool for cutting exhaust pipes without the need for a saw. It’s essentially a combination of three tools in one – an oscillating multi-tool, a router and a jigsaw – giving you lots of versatility when it comes to projects that require precision cutting. In terms of cutting an exhaust pipe, the Dremel Trio is perfect because it offers variable speed control, a strong cutting motion and minimal vibration. [1]

Try Bending

One way to cut an exhaust pipe without a saw is by bending it. This method works best if the exhaust pipe has thin walls, such as those found in many motorcycle and ATV systems. To do this, start by loosening the clamps at either end of the pipe and then slide the section of pipe you need to cut off. Next, use two hands to grab either end of the pipe and then bend it back and forth until it snaps. The force required to break the pipe varies depending on its thickness, so you may need to apply significant pressure in order to get a clean break. Once the exhaust pipe is broken, use a file or grinder to smooth down any rough edges. [2]

Angle Grinder

An angle grinder is the ideal tool for cutting an exhaust pipe without a saw. It’s a versatile tool that is perfect for getting the job done quickly and efficiently. The blade of an angle grinder can easily cut through metal and be adjusted to fit any size exhaust pipe, making it a great option if you don’t have access to a saw.

To use an angle grinder, first make sure the blade is sharp and securely fastened to the machine. Put on safety goggles and gloves before beginning. Then, measure the pipe length you need to cut off and mark it with a marker or tape measure. Place the exhaust pipe in a vice grip or secure it between two solid objects so that you can safely access. [2]

Tin Snips

Tin snips are a great tool for cutting an exhaust pipe without a saw. They have sharp blades that can easily cut through the metal of an exhaust pipe with minimal effort. This is especially helpful if you need to make small cuts or bends in your exhaust pipe. Tin snips are also relatively inexpensive and can be purchased at most hardware stores.

When using tin snips to cut an exhaust pipe, be sure to wear gloves and safety goggles for protection. Additionally, make sure that the blades of the tin snips are sharp so they can easily cut through the metal. [2]

Cordless Drill and MAPP Gas Torch

Using a cordless drill and MAPP gas torch is a great way to cut an exhaust pipe without using a saw. To start, you will need to make sure that the exhaust pipe is securely clamped in place so that it doesn’t move or vibrate while drilling. Next, use your cordless drill to drill into the pipe where you want to make your cut. Once the hole is created, place your MAPP gas torch in the hole and heat up the area until it starts to glow red hot. Finally, use a pair of pliers or tongs to break off the heated section of pipe, separating it from the rest. [2]

Cordless Drill and MAPP Gas Torch

Rotary Tool

One way to cut an exhaust pipe without a saw is with the help of a rotary tool. This type of tool has various attachments, such as grinding stones and cutting discs, which allow it to perform different tasks. To use this method:

  1. Start by finding the right attachment for your rotary tool – usually either a diamond-tipped cutting disc or a grinding stone works best.
  2. Next, ensure that the rotary tool is firmly secured in place with a vice grip or table clamp and attach the chosen attachment to the tool.
  3. Mark out the section of pipe you want to cut, and make sure your markings are clear and visible.
  4. Place the cutting end of the rotary tool onto your marked area, switch it on and slowly start to cut through the pipe. Note: caution should be taken when using this method as sparks can fly and cause injury.
  5. As you continue to cut the pipe, keep checking if you’re following the line of markings correctly. If needed, use a damp cloth to wipe away. [1]

Portable Hand cutting tools

If you don’t have a saw, you can use other portable hand cutting tools to cut your exhaust pipe. These include hacksaws, angle grinders, and reciprocating saws. Hacksaws are great for straight cuts and provide a clean edge with minimal effort. They are also fairly inexpensive and widely available. Angle grinders offer more precision than hacksaws and are great for cutting out sections of the pipe. You can use a grinding wheel to make precise cuts or even a diamond-tipped cutting wheel to cut through hard materials such as stainless steel. Reciprocating saws offer fast, precise cutting with minimal effort and can be used to make straight and curved cuts in your exhaust pipe. [1]

Tips for Cutting an Exhaust Pipe

If you need to cut an exhaust pipe without a saw, there are some important tips to keep in mind:

  • Use a clamp – A metalworking clamp can be used to hold the exhaust pipe securely while you use other tools to make the cut. Make sure that the clamp is tightly secured and won’t move as you work.
  • Use a hacksaw – If possible, use a metal-cutting hacksaw to make the cut. Be sure to apply pressure evenly and keep your sawing motion steady while cutting through the exhaust pipe.
  • Use a rotary tool – A rotary tool with an abrasive cutoff wheel can be used to make a clean cut without producing any sparks. Start off slow and gradually increase the speed as you make your cut.
  • Wear safety gear – No matter which tool you use to cut the exhaust pipe, be sure to wear safety goggles, gloves, and a dust mask for added protection against metal shavings. [1]

Tips for Cutting an Exhaust Pipe


How do you cut an exhaust pipe by hand?

Cutting an exhaust pipe by hand can be tricky, but it is possible to do so without the aid of power tools. The most common way to cut an exhaust pipe without a saw is to make use of a hacksaw. A hacksaw has a fine-toothed blade that can easily cut through metal pipes like an exhaust pipe. To begin cutting your exhaust pipe, you will first need to identify the point at which you want to make the cut. Once that is determined, mark it with a marker or pen so that the blade won’t slip off track during cutting. Next, use your hacksaw to slowly and steadily saw back and forth along the marked line until it has been completely cut through.

What is the best tool to cut exhaust pipes?

The best tool to cut exhaust pipes is a reciprocating saw, also commonly referred to as a “sawzall”. This powerful battery-operated or corded saw uses rapid back and forth motions of its blade to quickly cut through metal pipes with minimal effort. It is easy to use and much faster than hand tools such as a hacksaw. If you need to make cuts in an exhaust pipe in a hurry, a reciprocating saw is the way to go.

Is it safe to cut the exhaust pipe?

Yes, it is safe to cut an exhaust pipe as long as you take the necessary safety precautions. Wear protective gear such as gloves and eye protection when cutting with tools like a hacksaw or reciprocating saw. Make sure that the area around your work station is clear of any flammable materials and that the exhaust pipe is cool before beginning work on it.

Does cutting your exhaust make it louder?

No, cutting an exhaust pipe will not make it louder. If anything, the sound of your car may be slightly quieter after having cut the exhaust pipe due to the increased flow of gases through the system. However, any noticeable difference in sound should be minimal.

Why do people cut exhaust?

People often cut their exhaust for a variety of reasons. One of the most common reasons is to reduce the overall weight of the vehicle, which can help improve fuel economy and performance. Additionally, some people may choose to modify the sound or appearance of their car by shortening or removing sections of their exhaust pipe.

Can exhaust hurt you?

Yes, an exhaust pipe can be dangerous if handled improperly. Make sure that the temperature of the pipe is cool before attempting to work on it in order to avoid burns. It is also important to wear protective gear such as gloves and eye protection when cutting or handling an exhaust pipe.

Is exhaust bad for the engine?

No, exhaust is not bad for the engine. In fact, it is necessary for proper operation as it carries gases away from the engine. However, if an exhaust pipe becomes clogged or blocked due to rust or corrosion, this can cause a decrease in performance and could potentially damage your engine. Therefore, it is important to regularly inspect and maintain your exhaust system to ensure optimum engine performance.

These are just some of the frequently asked questions about cutting an exhaust pipe without a saw. Cutting an exhaust pipe can be tricky, but with the right tools and safety precautions, it is possible to do so without damaging your vehicle or yourself.

Do exhaust burns scar?

Yes, exhaust burns can scar if not treated properly. It is important to seek medical attention if you are burned by an exhaust pipe in order to reduce the risk of permanent damage or scarring. A doctor may recommend a burn cream or ointment to help treat the wound and prevent scarring.



Cutting an exhaust pipe without a saw is definitely possible if you have the right tools and knowledge. Grinders and cold cutters are ideal for this job, but you can also use a hacksaw or even an angle grinder as a last resort. However, it’s important to exercise caution when working with tools such as grinders and cold cutters, as they can be dangerous. Be sure to take all safety precautions necessary before attempting this job. With the right knowledge and tools, you should have no problem cutting an exhaust pipe without a saw. Good luck!