We tested models from the most trusted tool brands to see which could reliably handle fast, smooth cuts. Here are the options we recommend.
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While typical hand saws tackle wood cutting tasks just fine, harder materials require a hacksaw. These rugged tools have thin blades, small teeth, and a durable frame—all essential components for aggressively powering through metal and hard plastic.
Unlike other hand saws, hacksaws use a built-in tension system to keep their blades extremely taut, which makes them perfect for plumbing tasks that involve copper or PVC piping, as well as other home projects that require rebar or conduit trimming. While reciprocating saws offer more speed and demand less effort, the superior precision and convenience (no power source required) of hacksaws are worth the compromise.
Below, we’ve found the best hacksaws for any home improvement project. You’ll also find tips on what to consider when you’re trying to identify which hacksaw is ideal for you and your needs.
All hacksaw blades use their small teeth to smoothly cut through hard materials, but the number of teeth differs from blade to blade. Choose the best teeth per inch (TPI) for your specific application. As a general rule of thumb, the thicker the material, the fewer teeth you want.
Course-Grade (14-18 TPI): Use these blades on thicker and relatively soft materials, like aluminum, copper, and mild steel. Since course blades have fewer teeth, they produce rougher cuts than higher TPI options.
Medium-Grade (20-24 TPI): This is the most common hacksaw blade type. Blades in this TPI range provide a useful balance of aggressive cutting and smooth edges. In addition to metal, these blades effectively cut plastic and PVC. If you need a hacksaw for a wide range of tasks, go with a medium-grade blade.
Fine-Grade (24-30 TPI): Fine-grade blades produce very smooth cuts, although they take longer than lower-TPI blades to cut through thicker materials. Use them on thin or especially fragile workpieces.
Superfine-Grade (30-32 TPI): Anything higher than 30 TPI is considered “superfine” grade, which is ideal for cuts that leave no burrs or rough edges behind.
Carbon Steel: These basic blades are the best option for general use. Although carbon steel wears down faster than other materials, it’s versatile enough for a variety of applications and costs less than other types.
High-Speed Steel: Made of a steel alloy, these blades withstand the high temperatures generated by metal cutting. This heat resistance makes high-speed steel blades slower to wear down.
Bi-Metal: With a carbon-steel body and high-speed steel teeth, bi-metal blades strike the balance between durability and performance. These blades cost more than those made of 100 percent carbon steel or high-speed steel.
While all hacksaws have the same basic design—a blade suspended between a U-shaped frame—some convert into additional shapes and blade positions. Models with a “jab saw” option extend a pointed reciprocating saw blade and conveniently reach into tight areas that a standard hacksaw body could not.
On-board blade storage is another feature to look for. Many hacksaws have a hollow frame that stores multiple blades, which is handy for quickly replacing a worn-down blade in less than a minute. If you want to cut flush against a surface, look for a hacksaw with a pivoting blade position.
The longer the saw blade, the more metal it removes with each stroke. Most hacksaw blades are 10 to 12 inches in length, but they come as short as six inches. While longer blades offer more productivity, compact options fit more conveniently into tight or cramped areas.
All hacksaws hold their blades tightly in place to give you the necessary speed to always cut effectively, but some have more tension than others.
Standard-tension hacksaws use a basic wingnut to tighten the blade, and they cost less than other options. High-tension models use an expandable frame and powerful lever mechanisms to hold the blade extremely taut, practically eliminating any flexion or bending.
This story’s original author, test editor Roy Berendsohn, has used both standard and high-tension hacksaws in various carpentry, demolition, and plumbing projects. This experience has given him the necessary insight to assemble a pool of popular and well-regarded hacksaw choices from brands that he’s come to know and trust.
For models that Roy hadn’t used personally, he and his fellow members of the Popular Mechanics test team sourced samples and ran them through a comprehensive testing process, which involved cutting through half-inch rebar, 16D nails driven into a two-by-four, and PVC pipe. After the team’s research and testing, Roy evaluated the remaining options based on overall usability, functionality, and durability, finally landing on the best six options listed here.
Alex Rennie wrote the most recent update of the story. He added two hacksaws from respected hand tool brands Lenox and Stanley.
This DeWalt model offers an incredible amount of cutting versatility thanks to its two included blades and its ability to transform into five different saw shapes. The removable front handle and included reciprocating saw blade allow you to use both pieces for different tasks, such as a compact jab saw and a low-profile hacksaw.
The 12-inch blade even mounts to the main pistol grip for jobs that require an extra long reach without obstruction. Our test team found these different combinations simple to assemble, and thanks to the saw's straightforward design.
While at 2.3 pounds, it weighs more than most, this heavy-duty saw nonetheless absolutely powered through rebar, nail-studded wood, and PVC during testing.
Despite the low price, this Craftsman saw has a sturdy, well-made feel to it, from the individual components of the tension system to the handle. Our test team found it very straightforward to make adjustments to this standard-tension saw and mount the blade in either 90- or 45-degree positions.
The saw’s 12-inch length and nearly 4.5-inch cut depth maximize its overall versatility—it helps complete a wide range of basic cutting tasks—and its 1.23-pound weight minimizes hand and arm fatigue. It didn’t cut as fast as the higher-end saws, and it lacks the tautness of models with higher tension, but it still did a fine job with the rebar, framing nail, and PVC tests. It lacks blade storage though, so it’s perhaps not an ideal choice for frequent users.
If you need to access spaces too cramped or awkward for a typical hacksaw frame to fit, consider this six-inch mini hacksaw. Since this model still accepts standard 10-inch blades, you don’t even sacrifice that much cutting capacity (though it’s still not especially practical for more heavy-duty tasks).
Made entirely out of corrosion-resistant aluminum, this saw is practically indestructible and provides the structural integrity necessary to saw through tough tubing and bolts. Leonx tools are designed with comfort and usability in mind, a quality clearly shown in the exaggerated ergonomics of the handle grip.
With an arc-shaped frame and narrow nose, this Stanley saw fits easily into tight, hard-to-reach areas. The heavy-duty aluminum frame has the strength and durability necessary for frequent use, and its light weight—just 1.1 pounds—places minimal strain on your wrist and forearms.
The saw’s uncommon shape results in a slightly shorter throat depth of four inches (most hacksaws have at least 4.375 inches of depth), but it’s still sufficient for the majority of PVC cutting tasks. The ergonomic handle provides a sturdy grip, and the tension knob gives you the ability to change blades and adjust tension quickly.
Lenox saws are known for their high-quality construction and overall durability, and this model also features a notably comfortable handle. The rubbery grip is a joy to hold, especially during strenuous tasks that would otherwise cause discomfort in your palm and wrist.
This versatile saw is on the heavier side, but it also has the storage space for up to five spare blades, and since it accepts any Lenox reciprocating blade (sold separately), it converts to a jab saw whenever you need one.
This compact saw, also from Lenox, features the thin blade and short body needed for small-scale metalwork, hobby or craft projects, and other fine-finish jobs. This small size also matches well with flush-cutting applications, and the blade’s 32 TPI results in a very smooth cut surface without the burrs left by larger blades with fewer teeth per inch.
This blade lacks the adjustability of other saws though, so it’s less versatile than models that have the ability to mount at angles other than 90 degrees. Despite the small size, the all-metal frame and handle are impressively durable. The saw has no plastic components to crack or snap unexpectedly.
Alex Rennie is a freelance writer who specializes in the Home Improvement, DIY, and Tool space. As a former residential and commercial carpenter, Alex uses his hands-on experience to write practical buying guides, how-to articles, and product reviews. His work has also appeared in Business Insider's Insider Picks, and before his writing career, he was a full-time carpenter living in New York City. There, he worked as part of a team designing, building, and installing large furniture pieces, as well as performing a variety of home repair and maintenance projects. Alex currently lives in Los Angeles, CA, and spends his free time exploring the beaches and mountains with his fiancé and their dog Louie.
Roy Berendsohn has worked for more than 25 years at Popular Mechanics, where he has written on carpentry, masonry, painting, plumbing, electrical, woodworking, blacksmithing, welding, lawn care, chainsaw use, and outdoor power equipment. When he’s not working on his own house, he volunteers with Sovereign Grace Church doing home repair for families in rural, suburban and urban locations throughout central and southern New Jersey.
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