If you’re installing heavy-duty wire shelving with thicker than normal wires, opt for bolt cutters with longer handles. The longer the handles, the more cutting power. You can buy bolt cutters for under $20 USD at many home improvement retailers, or you may be able to rent them from a tool rental shop. As an alternative, try using dikes, or diagonal pliers. Always wear eye protection when using bolt cutters or other tools. Even though they rarely create metal shards when cutting, there’s always a small chance of getting small, sharp pieces of metal debris in your eye.
For instance, say you have 2 sections of 24 in (61 cm) long shelving and want to fit them into a 37 in (94 cm) wide closet. In this case, adjust your length measurement to 36 in (91 cm) and mark the pieces as desired—either one whole section and one 12 in (30 cm) section, or two 18 in (46 cm) sections.
Squeeze the shelf at or just above your ankles so that you have at least 2–3 in (5. 1–7. 6 cm) of clearance off the ground. Position the shelf so that your cutting point is about 3–4 in (7. 6–10. 2 cm) in front of your legs. However, if you need to cut the shelving near either of your feet, re-position the shelving so the cutting point is 2–3 in (5. 1–7. 6 cm) beyond your toes.
For most shelving cuts—for instance, trimming 1 ft (30 cm) from the length of a shelf section so it fits inside your pantry—you’ll need to cut through a series of wires. Mark each wire individually, and cut through them sequentially.
If you’re using an older set of bolt cutters with dulled edges on the jaws, you can sharpen them by passing a metal mill file back and forth a few times over each jaw blade, making sure to follow the existing bevel of the edges. Alternatively, a machine shop, tool rental store, or home improvement retailer may offer sharpening services. [5] X Research source You can buy a mill file at any tool retailer.
Instead of filing down the burrs, or in addition to doing so, you can cover the cut edges with the plastic caps that come with many wire shelving sets—they look like small soda bottle caps. Just press them firmly over the cut ends of the wires until they are securely in place.
Transfer your measurements to the shelving with a permanent marker so they’re easy to see while cutting.
You can also use a sturdy table, but make sure you protect its top with the towel.
You can make spring-loaded clamps, C-clamps, or practically any other type of workshop clamp work for this application. Use at least two clamps. Secure them to the underside of the table and the top of the shelving where it starts to extend out over the edge of the table. Add more clamps for extra security. Make sure the clamps are tight, but not so tight that they dent or bend the shelf wires. In a pinch, you can make your own padded clamps by putting strips of cloth between the clamp and the shelving.
Hacksaws are made for cutting through metal, so a standard cutting blade will do the job well here. If your blade has dulled from use, you can easily replace it with a new one. Simply loosen the wingnut above the handle, remove the old blade, set the new one in place, and re-tighten the wingnut. A cordless bandsaw could also work to cut through wire. Wear eye protection, work gloves, and long sleeves when using a hacksaw or any hand saw.
It takes a lot longer to cut with a mini hacksaw, so only use it when the bigger version won’t fit. If you’re simply cutting pieces of shelving to length—which is typical in most applications—you’ll almost certainly be able to make all the cuts with a standard hacksaw.
Run the mill file back and forth over the cut metal a few times to smooth it out. Press the caps on firmly until they are securely in place. Even if you work slowly and carefully, using a hacksaw will create rougher cuts and more burrs than will using bolt cutters.
Dremel is the best-known brand of rotary tool, but there are several different manufacturers. Compare options at your local home improvement store. Alternatively, use an angle grinder with a metal cutting blade. Always take proper safety precautions before using a rotary tool. Wear eye protection and long sleeves, put on thick work gloves, remove any dangling jewelry, and tie back any long hair. You should also use hearing protection.
Rotary tools vary in how you secure the attachments and turn on the motor, so read your product instructions carefully. If you need to cut through several pieces of shelving, you’ll likely wear out multiple cutting wheels—so buy several backups before you start cutting.
If your wire shelving kit comes with plastic end caps that look like small soda bottle caps, press them firmly onto each cut wire end until they’re securely in place. This will provide extra protection against any burrs that might still be present.
