How to Cut Flexible Electrical Conduit

Many projects involving electrical wiring will require the use of a flexible electrical conduit. While a flexible electrical conduit is quite useful and much easier to work with than other varieties of electrical conduits, the truth is that cutting it effectively can be quite a challenge. This is especially true if you consider the precision with which an electrical conduit must be cut in order to be in any way usable. However, with the right techniques, strategies and tools, cutting a flexible electrical conduit is quite doable for a person with no particular experience. What follows should give you everything you need to know in order to successfully cut a flexible electrical conduit.

Step 1 - Setup

Before you do anything, make sure that your section of electrical conduit does not contain any electrical wires. While this is unlikely, if you are modifying an existing setup, it is quite possible. Once you have verified that your electrical conduit is free of wires, bring it to your vise and locate the rest of your equipment.

Step 2 - Measuring

Before cutting your flexible electrical conduit, you must measure it accurately so that it will fit in with the rest of the work that you are doing. First, figure out exactly what size piece or pieces (if you are planning to make multiple cuts) of electrical conduit you will need for your project. Once you have done this, use your measuring tape to measure the size of electrical conduit. Mark the measurement with your pen.

Keep in mind that you will have to cut your flexible electrical conduit at a 90 degree angle. Make sure that the mark you make allows the conduit to be cut at this angle.

Step 3 - Cutting

While it is not strictly necessary, it is very helpful to have a system to hold your section of flexible electrical conduit perfectly in place while you cut it. This is particularly true when you realize that you must cut at 90 degrees. The best way to hold your flexible electrical conduit in place is with a vise. Place your flexible electrical conduit in your vise and tighten it until it will not move. Once you have done this, you can use your hacksaw to cut it.

Make sure that your cut is at 90 degrees perpendicular to the length of the flexible electrical conduit, and not at another angle. Additionally, make sure that your hacksaw is in good condition and has at least 18 teeth per inch.

Once you have made the necessary cuts, you can continue.

Step 4 - Finishing Up

Chances are good that you are done. However, if there are imperfections on the edges of your cuts, you will need to fix them before putting your sections of flexible electrical conduit into use. File the ends of your flexible electrical conduits until there are no more imperfections.

Additionally, you should use a rat-tail file to ream the inside of the electrical conduit, as there may be imperfections there as well. Once both the end and inside of your flexible conduits are smooth, you may use them in your project.