DIY Network

How to Cut and Bend Flat Bar Stock

Learn how to cut and bend a flat bar stock using a chop saw and a plywood jig.

More in Home Improvement

  • Time

    30 Minutes

  • Price Range

    $100 - $250

  • Difficulty

    Easy to Moderate


Step 1: Choose the Blade Type

This chop saw has carbide teeth that are set flush to the body of the saw and have a slight negative hook for working with metal. The blade is designed to work with aluminum or steel. Use a blade that is designed for the kind of metal you are working with.

An overload switch acts like a breaker, stopping the motor if metal catches between the blade teeth. A metal shield offers protection from flying metal.

chop blade designed to work with aluminum or steel

Step 2: Adjust the Saw Angle

The base of the unit features a moveable fence. Use a socket wrench to release the bolt holding the fence in place; adjust to the angle needed.

Step 3: Make a Cut

A vise holds the material against the face of the fence. Slide the vise back and forth to move quickly; use the handle to move slowly and in small increments.

To make a cut, place the metal between the fence and the vise. Then engage the trigger and pull it down into the cut.

Step 4: Bend the Bar Stock

To bend flat bar stock, make a jig out of plywood. The jig is a plywood square with a circle mounted to it. The circle has a slot cut into it. Place the end of the bar stock into the slot and bend the bar tightly around the circle (Image 1).

Bend the other end of the bar in the opposite direction to make an 'S' shape (Image 2).