How To Change A Blade On A Reciprocating Saw: Step-by-Step

Changing a blade on a reciprocating saw, including a Sawzall, is easy. You simply need to know the type of blade locking mechanism your saw has and follow the correct steps to safely remove the old blade and install a new one. This guide provides a step-by-step process for reciprocating saw blade replacement, ensuring you can tackle any cutting task with confidence.

Image Source: i.ytimg.com

Getting Ready for Reciprocating Saw Blade Replacement

Before starting the sawzall blade change, gathering the right tools and taking safety precautions are key.

Essential Tools and Materials

Having these items on hand will make the process smoother:

• New reciprocating saw blade(s) – Choose the right blade for the material you’ll be cutting.
• Work gloves – To protect your hands.
• Safety glasses – To shield your eyes from debris.
• A cloth or rag – For cleaning the blade and saw.

Safety First

Safety is paramount. Remember these points:

• Unplug the Saw: Always disconnect the reciprocating saw from the power source (or remove the battery) before any blade changes. This prevents accidental starts.
• Wear Protective Gear: Gloves and safety glasses are a must. Reciprocating saw blade removal can sometimes involve sharp edges and flying debris.
• Inspect the Blade: Check the new blade for any damage before installing it.
• Secure the Workpiece: Make sure the material you’re cutting is firmly secured before you start sawing.

Deciphering Reciprocating Saw Blade Locking Mechanisms

There are different ways reciprocating saws hold blades.

Tool-Free Blade Change Systems (Quick Release)

Many modern reciprocating saws have a tool-free system. This makes sawzall blade change very easy. These systems generally involve a lever, button, or collar that you can manipulate by hand to release and secure the blade. This is often referred to as a quick release reciprocating saw blade system.

Tool-Based Blade Change Systems

Older or some budget-friendly models might require a tool, usually an Allen wrench or hex key, to loosen and tighten a set screw that holds the blade in place.

Feature	Tool-Free Systems	Tool-Based Systems
Blade Changes	Fast and easy, no tools required.	Requires a tool, making changes slower.
Convenience	Very convenient, especially on the job site.	Less convenient, especially if you lose the tool.
Commonality	Found on most newer models.	Typically found on older or less expensive models.
Parts Needed	Usually only the blade itself.	Allen wrench or hex key and blade.

Step-by-Step Guide to Changing a Reciprocating Saw Blade

Here’s a detailed breakdown of the blade change process:

Step 1: Removing the Old Reciprocating Saw Blade

For Tool-Free Systems:

1. Locate the Release Mechanism: Find the lever, button, or collar near where the blade is inserted.
2. Activate the Release: Depending on the design, you may need to push, twist, or pull the lever/button/collar. The mechanism should release the old blade.
3. Remove the Old Blade: Carefully pull the blade out of the holder. Be cautious, as the blade might be hot or have sharp edges. Use gloves!
4. Dispose of the Blade Safely: Wrap the old blade in cardboard or heavy tape before throwing it away to prevent injuries.

For Tool-Based Systems:

1. Locate the Set Screw: Find the set screw near the blade holder.
2. Loosen the Set Screw: Use the correct size Allen wrench or hex key to loosen the set screw. Don’t remove the screw completely; just loosen it enough to release the blade.
3. Remove the Old Blade: Carefully pull out the old blade.
4. Dispose of the Blade Safely: Wrap the old blade in cardboard or heavy tape before throwing it away.

Step 2: Installing the New Reciprocating Saw Blade

For Tool-Free Systems:

1. Orient the New Blade: Make sure the teeth of the blade are facing in the correct direction (usually pointing forward).
2. Insert the New Blade: Push the blade into the holder until it clicks or locks into place.
3. Secure the Blade: Ensure the blade is firmly secured. Try gently pulling on it to make sure it won’t come loose during operation.
4. Test: Before using the saw, turn it on briefly to ensure the blade is running correctly.

For Tool-Based Systems:

1. Orient the New Blade: Make sure the teeth of the blade are facing in the correct direction.
2. Insert the New Blade: Insert the new blade into the holder, aligning it with the set screw.
3. Tighten the Set Screw: Use the Allen wrench or hex key to tighten the set screw, securing the blade in place. Don’t overtighten, as this could damage the screw or blade.
4. Test: Before using the saw, turn it on briefly to ensure the blade is running correctly.

Step 3: Final Checks

After installing the blade:

• Visual Inspection: Double-check that the blade is properly seated and secured.
• Manual Test: Gently tug on the blade to ensure it’s locked in.
• Functional Test: Briefly turn on the saw (without cutting anything) to make sure the blade runs smoothly and doesn’t wobble.

Tips for a Smooth Reciprocating Saw Blade Change

Keep these tips in mind:

• Clean the Blade Holder: Before inserting a new blade, use a cloth to clean any debris from the blade holder. This will ensure a secure fit.
• Use the Right Blade: Choose a blade specifically designed for the material you’ll be cutting (wood, metal, plastic, etc.). Using the wrong blade can damage the blade and the material.
• Apply Lubricant (if needed): Some metal-cutting blades benefit from lubrication. Check the blade manufacturer’s recommendations.
• Check for Wear and Tear: Regularly inspect the blade holder and locking mechanism for wear and tear. If you notice any damage, have the saw repaired by a qualified technician.

Troubleshooting Common Issues

Blade Won’t Release:

• Tool-Free: Make sure you’re fully engaging the release mechanism. Sometimes, a bit of pressure or jiggling can help.
• Tool-Based: Ensure the set screw is sufficiently loosened. If it’s stuck, try applying penetrating oil.

Blade Won’t Lock In:

• Debris: Clean the blade holder thoroughly.
• Damage: Inspect the blade holder and the blade for any damage.
• Incorrect Blade: Make sure you’re using the correct type of blade for your saw.

Blade Wobbles:

• Loose Connection: Ensure the blade is fully seated and locked in.
• Damaged Blade Holder: A damaged blade holder can cause the blade to wobble. Have the saw repaired.
• Bent Blade: A bent blade can cause a wobble. Replace the blade.

Selecting the Right Reciprocating Saw Blade

Choosing the correct universal reciprocating saw blade for the job is essential for efficient and safe cutting. Blades are designed for specific materials and purposes.

Material Compatibility

• Wood Blades: These blades typically have larger teeth and are designed for fast cutting in wood.
• Metal Blades: Metal blades have finer teeth and are made from tougher materials to withstand the rigors of cutting metal.
• Bi-Metal Blades: These blades combine the flexibility of high-speed steel with the durability of carbon steel, making them versatile for cutting various materials.
• Specialty Blades: There are also blades designed for specific materials like plaster, fiberglass, or even demolition work.

Teeth Per Inch (TPI)

The number of teeth per inch (TPI) affects the cutting speed and smoothness:

• Lower TPI (6-10 TPI): Faster cutting, but rougher finish. Best for thick materials and demolition work.
• Higher TPI (14-24 TPI): Slower cutting, but smoother finish. Best for thin materials and precision cuts.

Blade Length

The blade length should be appropriate for the material you’re cutting. A longer blade is needed for cutting through thicker materials. Avoid using a blade that is too long, as it can be difficult to control.

Blade Thickness

Thicker blades are more rigid and resist bending, which is beneficial for straight cuts and demanding applications. Thinner blades are more flexible and can be useful for curved cuts or tight spaces.

Blade Material

• High-Speed Steel (HSS): Offers good heat resistance and is suitable for cutting softer metals and wood.
• Carbon Steel: A good choice for general-purpose cutting of wood and plastics.
• Bi-Metal: Combines the flexibility of HSS with the durability of carbon steel.
• Carbide-Tipped: Provides exceptional durability and is ideal for cutting hard materials like cast iron, stainless steel, and abrasive materials.

Here is a table summarizing blade selection based on material and TPI:

Material	TPI Range	Blade Material	Application
Wood	6-10	Carbon Steel	Fast cuts in lumber, demolition
Metal	14-24	Bi-Metal, HSS	Pipes, sheet metal, rebar
Stainless Steel	18-24	Bi-Metal, Carbide	Corrosion-resistant materials
Plastic	10-14	Carbon Steel	PVC, ABS, acrylics
Demolition	6-10	Bi-Metal, Carbide	Nail-embedded wood, mixed materials

The Importance of Regular Blade Changes

Regular reciprocating saw blade replacement ensures optimal performance, safety, and extends the life of your saw. Dull blades require more force, which can strain the motor and increase the risk of kickback. A sharp blade cuts more efficiently, resulting in cleaner cuts and reduced effort. Replacing a worn blade is a quick and easy maintenance task that pays off in the long run.

FAQ: Changing Reciprocating Saw Blades

• What is the best way to dispose of old reciprocating saw blades? Wrap them in cardboard or heavy tape to prevent injuries and then dispose of them in a designated metal recycling container.

• Can I use any reciprocating saw blade with any reciprocating saw? Most reciprocating saws use a universal shank that accepts standard reciprocating saw blades, but it’s always a good idea to check your saw’s manual to confirm compatibility.

• How often should I change my reciprocating saw blade? Change your blade when it becomes dull, bent, or damaged. The frequency depends on the type of material you’re cutting and how often you use the saw.

• Who can change a reciprocating saw blade? Anyone who understands the tool’s operation and follows safety guidelines can change a reciprocating saw blade.

• How to replace sawzall blade that is stuck? First, ensure the blade release mechanism is fully engaged. If the blade is still stuck, try applying penetrating oil to the blade holder and gently wiggling the blade back and forth. If needed, use pliers to grip the blade firmly and pull it out. Be cautious to avoid injury.

By following these steps and tips, you can easily and safely perform reciprocating saw blade replacement, ensuring your saw is always ready for the task at hand. Remember to always prioritize safety and choose the right blade for the job.