Welded wire fence is a versatile and robust fencing solution commonly used for everything from containing livestock and protecting gardens to marking property lines and enhancing security. Its strength and durability are undeniable assets, but when it comes time to cut or modify it, many find themselves facing a frustrating challenge. Fear not! This comprehensive guide will equip you with the knowledge and skills needed to cut welded wire fence safely and effectively, regardless of the project at hand.
Understanding Welded Wire Fence
Before we dive into the cutting process, it’s essential to understand the nature of the material you’re working with. Welded wire fence, as the name suggests, consists of intersecting wires joined together by welds at each intersection point. These welds are crucial to the fence’s structural integrity. Cutting the wire compromises this integrity, so careful planning and proper technique are key to a successful outcome.
Welded wire fences come in a variety of gauges (wire thickness), mesh sizes (the size of the openings), and coatings. The gauge of the wire will directly impact the tools you need and the difficulty of the cut. Thicker gauge wire requires more robust tools. Mesh size affects how easily you can navigate your cutting tool within the fence. Coatings, such as galvanized or PVC-coated, provide corrosion resistance and influence the cutting tool’s wear.
Types of Welded Wire Fence
There are several types of welded wire fence available, each designed for specific applications. Understanding these differences is crucial for selecting the appropriate cutting technique.
- Galvanized Welded Wire Fence: This is the most common type, featuring a zinc coating that protects the steel wire from rust and corrosion. Galvanization can be applied before (GBW) or after (GAW) welding. GAW fences generally have a longer lifespan.
- PVC-Coated Welded Wire Fence: This type adds a layer of PVC plastic over the galvanized wire, providing even greater protection against the elements and creating a visually appealing finish. The plastic coating can make cutting slightly more difficult, requiring sharper blades and potentially more force.
- Stainless Steel Welded Wire Fence: This is the most durable and corrosion-resistant option, ideal for harsh environments. However, it is also the most expensive and can be more challenging to cut due to the steel’s hardness.
Safety First: Essential Protective Gear
Cutting welded wire fence can be hazardous if proper precautions are not taken. Flying wire fragments, sharp edges, and the potential for tool slippage all pose risks. Always wear appropriate safety gear to protect yourself from injury. The following items are essential:
- Safety Glasses: Protect your eyes from flying wire fragments. This is non-negotiable.
- Work Gloves: Provide a firm grip on the tools and protect your hands from cuts and abrasions. Leather gloves are a good option.
- Long Sleeves and Pants: Minimize skin exposure to prevent cuts and scrapes from sharp wire ends.
- Steel-Toed Boots (Optional but Recommended): Protect your feet from dropped tools and sharp wire pieces on the ground.
Choosing the Right Cutting Tools
The right tool for the job depends on the gauge of the wire, the type of fence, and the precision required. Here’s a breakdown of common tools and their suitability for cutting welded wire fence:
Bolt Cutters
Bolt cutters are arguably the most versatile and widely used tool for cutting welded wire fence. They come in various sizes, ranging from compact models for lighter-gauge wire to heavy-duty options for thicker gauges. The longer the handles, the greater the leverage and cutting power. Bolt cutters are ideal for making straight cuts and for removing larger sections of fence. When selecting bolt cutters, consider the maximum cutting capacity specified by the manufacturer. Ensure it exceeds the diameter of the wire you’ll be cutting.
Wire Cutters (Pliers)
Wire cutters, also known as diagonal pliers or side cutters, are suitable for cutting thinner gauge wire. They provide greater precision than bolt cutters, making them useful for detail work, such as trimming wire ends or making small adjustments. However, they lack the leverage to cut thicker wires effectively.
Angle Grinder with a Cutting Disc
An angle grinder equipped with a metal cutting disc is a powerful tool that can quickly cut through even the thickest welded wire fence. However, it requires greater skill and caution than other methods. Angle grinders produce sparks and can generate significant heat, so it’s crucial to wear appropriate safety gear and work in a fire-safe environment. Always use a cutting disc specifically designed for metal.
Reciprocating Saw with a Metal Cutting Blade
A reciprocating saw, also known as a Sawzall, can be used to cut welded wire fence, particularly when you need to make long, straight cuts or cut through multiple wires simultaneously. Use a metal cutting blade with a high tooth count for best results. Like angle grinders, reciprocating saws can generate sparks and require careful handling.
Hacksaw
A hacksaw, with its fine-toothed blade, is a manual option that can be used to cut welded wire fence. While it requires more effort than power tools, it offers greater control and precision. Hacksaws are suitable for smaller projects or when you need to make intricate cuts.
Step-by-Step Guide to Cutting Welded Wire Fence
Now that you understand the types of fences, the necessary safety gear, and the available tools, let’s walk through the process of cutting welded wire fence.
Preparation is Key
Before you start cutting, take the time to plan your cuts. Mark the areas you intend to cut with a marker or tape. This will help you ensure accuracy and avoid mistakes. Clear the area around the fence of any obstacles that could hinder your work.
If the fence is under tension, it’s crucial to relieve the tension before cutting. Otherwise, the wires could snap back violently, posing a safety hazard. You can use fence stretchers or come-alongs to temporarily secure the fence and relieve tension.
Cutting with Bolt Cutters: A Common Method
- Position the bolt cutter blades around the wire you want to cut, ensuring the wire is as close to the hinge point of the blades as possible. This maximizes leverage.
- Apply firm, even pressure to the handles of the bolt cutters. Avoid jerky movements, which can damage the blades or cause the wire to slip.
- Continue applying pressure until the wire is completely severed.
- Repeat the process for each wire you need to cut.
Cutting with an Angle Grinder: For Heavy-Duty Jobs
- Secure the fence to prevent it from moving during cutting.
- Put on your safety glasses, gloves, and hearing protection. Angle grinders are loud and produce flying sparks.
- Start the grinder and allow it to reach full speed.
- Gently lower the cutting disc onto the wire, using a smooth, controlled motion. Avoid forcing the disc, as this can cause it to bind or break.
- Cut through the wire completely. Be mindful of the sparks and hot metal fragments.
- Turn off the grinder and allow the disc to stop spinning before setting it down.
Cutting with Wire Cutters: For Fine Detail Work
- Position the wire cutter blades around the wire you want to cut.
- Squeeze the handles firmly to sever the wire.
- Use the wire cutters to trim any sharp edges or protruding wire ends.
Cutting with a Reciprocating Saw: Long, Straight Cuts
- Secure the fence. This is especially important when using a reciprocating saw, as the vibration can cause the fence to move.
- Insert a metal cutting blade into the saw.
- Position the blade against the wire you want to cut.
- Start the saw and apply gentle pressure to guide the blade along the cutting line.
- Maintain a steady pace and avoid forcing the blade.
Cutting with a Hacksaw: For Precision and Control
- Secure the fence to prevent it from moving.
- Position the hacksaw blade against the wire you want to cut.
- Apply gentle pressure and begin sawing in a smooth, back-and-forth motion.
- Maintain a consistent pace and avoid forcing the blade.
Dealing with Sharp Edges and Wire Ends
After cutting welded wire fence, you’ll inevitably be left with sharp edges and protruding wire ends. These can be hazardous, so it’s essential to address them properly.
- Bend over sharp ends: Use pliers to bend the sharp ends of the cut wires over onto themselves. This will create a loop and reduce the risk of injury.
- Use wire caps: Wire caps are small plastic or rubber caps that can be placed over the ends of the cut wires. They provide a protective barrier and prevent cuts and scrapes.
- File down sharp edges: If bending or capping the wire ends isn’t feasible, you can use a metal file to smooth down the sharp edges.
Tips for a Clean and Professional Cut
- Use sharp blades: Dull blades require more force and can result in jagged cuts. Replace blades regularly to ensure optimal performance.
- Cut at a slight angle: Cutting the wire at a slight angle can help to prevent it from fraying.
- Avoid cutting welds: Cutting directly through the welds can weaken the fence and make it more prone to unraveling.
- Take your time: Rushing the cutting process can lead to mistakes and injuries. Work slowly and deliberately to ensure a clean and professional cut.
- Protect coated fences: When cutting PVC-coated fences, be extra careful not to damage the coating. Use sharp blades and avoid excessive force. Consider using a lubricant, such as WD-40, to help the blade glide through the coating more smoothly.
Maintenance and Repair After Cutting
Cutting welded wire fence can compromise its integrity, so it’s essential to perform any necessary maintenance and repairs to ensure its long-term durability.
- Repairing cuts: If you’ve made a mistake and cut the fence in the wrong place, you can repair it using wire connectors or by weaving new wire into the existing mesh.
- Preventing rust: After cutting galvanized wire fence, the exposed steel at the cut ends is susceptible to rust. Apply a cold galvanizing compound to these areas to protect them from corrosion.
- Regular inspection: Regularly inspect your welded wire fence for any signs of damage or wear. Promptly repair any problems to prevent them from escalating.
Cutting welded wire fence doesn’t have to be a daunting task. By understanding the material, choosing the right tools, following safety precautions, and employing proper techniques, you can achieve clean, professional cuts and maintain the integrity of your fence for years to come.
What are the best tools to use for cutting welded wire fence, and why?
The best tools for cutting welded wire fence depend on the wire gauge and project size. Bolt cutters are ideal for thicker wire and provide significant leverage, making clean cuts with minimal effort. Angle grinders with a metal cutting disc offer a faster solution for larger projects but require more safety precautions. Avoid using dull tools like pliers as they will bend and deform the wire instead of cutting it cleanly.
Beyond choosing between bolt cutters and an angle grinder, consider the handle length of your bolt cutters for added leverage. For an angle grinder, select a thin cutting disc specifically designed for metal to minimize heat buildup and create cleaner cuts. Always wear appropriate safety gear like eye protection and gloves, regardless of the tool you choose, to prevent injury from flying wire or sparks.
How can I ensure I’m cutting the welded wire fence safely?
Safety is paramount when working with welded wire fence. Always wear safety glasses or a face shield to protect your eyes from flying debris. Gloves are also essential to protect your hands from sharp edges and cuts. It’s crucial to clear the area around the fence of any obstacles or tripping hazards.
Furthermore, when using an angle grinder, make sure the area is well-ventilated to prevent inhalation of metal dust. Secure the fence section you are cutting to prevent it from snapping or shifting unexpectedly. If using bolt cutters, maintain a firm grip and stable stance to avoid losing control of the tool. Always prioritize slow, controlled cuts over rushing the process.
What is the best technique for cutting welded wire to minimize sharp edges?
To minimize sharp edges, cut the wire as close as possible to the vertical or horizontal wire where they intersect, creating a more stable and less protruding point. Avoid cutting directly in the middle of a wire section, as this leaves a sharp, exposed end. Another effective technique is to use a cold chisel and hammer to shear the wire at the weld point, leaving a cleaner break.
After cutting, use a file or metal grinding wheel to deburr any remaining sharp edges. This process removes any burrs or rough spots, significantly reducing the risk of injury. If possible, consider folding or bending the cut ends back onto the fence itself to further encapsulate the sharp points.
How do I cut welded wire fence to create a specific shape or size?
Start by accurately measuring and marking the desired shape or size on the fence with a marker or chalk. This ensures precise cuts and minimizes errors. Use a straight edge, such as a level or a piece of lumber, as a guide to maintain straight lines when cutting. Remember to account for any overlapping or joining sections.
For complex shapes, create a template out of cardboard or paper and trace it onto the fence. Make small, incremental cuts following the marked lines rather than trying to cut through the entire section at once. This allows for greater control and reduces the chances of bending or distorting the wire. Regularly check your measurements and adjust as needed to maintain accuracy.
How do I join cut sections of welded wire fence together?
The best methods for joining cut sections of welded wire fence depend on the application and desired level of durability. Hog rings and hog ring pliers are a common and relatively easy solution, creating a secure connection by crimping the rings around the overlapping wires. Wire ties or zip ties can provide a temporary or less permanent solution, suitable for lighter-duty applications.
For a more permanent and robust connection, consider using wire clamps or U-bolts designed specifically for fencing. These provide a stronger hold and are less likely to loosen over time. Welding is the most durable option but requires specialized equipment and skills. Overlap the wire sections by at least a few inches and secure them at multiple points to ensure a strong and stable joint.
What should I do with the scrap pieces of welded wire fence after cutting?
Proper disposal of scrap welded wire fence is essential for safety and environmental reasons. Collect all the scrap pieces immediately after cutting to prevent tripping hazards or injuries. Larger pieces can be recycled at a metal recycling facility, which is the most environmentally responsible option.
Smaller pieces that are not recyclable can be disposed of in the trash, but ensure they are bundled and secured to prevent them from poking through trash bags. Consider reusing smaller scraps for other projects, such as creating garden supports or small animal enclosures. Always wear gloves when handling scrap wire to protect your hands from sharp edges.
What are some common mistakes people make when cutting welded wire fence, and how can I avoid them?
One common mistake is using the wrong tools, like dull pliers, which can bend the wire instead of cutting it cleanly. Using the proper tools, such as bolt cutters or an angle grinder, is essential for a professional-looking cut. Another mistake is not wearing proper safety gear, like safety glasses or gloves, which can lead to injuries from flying debris or sharp edges.
Another frequent error is rushing the cutting process, which can result in inaccurate cuts or damage to the fence. Taking your time and carefully following marked lines is crucial for achieving the desired results. Also, neglecting to deburr the cut ends can leave sharp edges that pose a safety hazard. Always file or grind down any sharp edges after cutting to minimize the risk of injury.