Milwaukee Band Saw Blade 35 3/8: Choosing the Right TPI and Tooth Profile
You own a Milwaukee M18 FUEL Compact Band Saw (2829-20) and you need to order replacement blades. The saw takes 35-3/8 inch blades. You see three TPI options: 14, 18, and 24. You are not sure which one to use for the kind of work you do, which is mostly cutting conduit, thin-wall pipe, and unistrut on electrical jobs.
The 35-3/8 inch blade is used by the Milwaukee M18 FUEL Compact (2829-20), the Milwaukee corded compact (6230-20), and the older M18 compact (2629-20). It is also shared with the DEWALT 20V mid-size saw (DCS378B). Blades are interchangeable between these models.
Blade Specifications
| Specification | Value |
|---|---|
| Length | 35-3/8 inches |
| Width | 1/2 inch |
| Thickness | 0.020 inches |
| Material | Bi-metal M42 |
| Fits | Milwaukee 2829-20, 6230-20, 2629-20; DEWALT DCS378B |
Available TPI Options
| TPI | Part Number | Best For |
|---|---|---|
| 14 | 48-39-0518 | Medium wall pipe, thin bar stock, aluminum |
| 18 | 48-39-0519 | Conduit, thin-wall tubing, general purpose |
| 24 | 48-39-0520 | Sheet metal, small round stock |
TPI Selection Guide
14 TPI (Part 48-39-0518)
Best for: Medium wall pipe (up to 2 inches), thin bar stock (1/4 to 1 inch), aluminum, and angle iron.
The 14 TPI is the coarsest blade available for the 35-3/8 inch length. It is designed for material 1/4 to 1 inch thick. The coarser teeth bite deeper and clear chips faster than finer blades.
When to use 14 TPI:
- Cutting medium wall steel pipe
- Cutting aluminum bar and angle
- Cutting thin solid bar stock
- When you need faster cutting speed and can accept a slightly rougher finish
When not to use 14 TPI:
- Very thin material (under 1/4 inch) where the coarse teeth will grab and tear
- Sheet metal where a fine finish is needed
18 TPI (Part 48-39-0519)
Best for: Conduit, thin-wall tubing, unistrut, and general-purpose cutting.
The 18 TPI is the general-purpose blade and the factory standard. It handles the widest range of materials and is the best starting point for most users.
When to use 18 TPI:
- Cutting EMT and rigid conduit
- Cutting thin-wall steel tubing
- Cutting standard 1-5/8 inch unistrut
- General-purpose metal cutting where you do not want to change blades frequently
When not to use 18 TPI:
- Very thick solid bar (over 1 inch) where the fine teeth will burn
- Very thin sheet metal where 24 TPI gives a cleaner cut
24 TPI (Part 48-39-0520)
Best for: Sheet metal, small round stock (under 1/4 inch), and very thin-wall tubing.
The 24 TPI is the finest blade available for the 35-3/8 inch length. It is designed for very thin material where fine teeth prevent grabbing and tearing.
When to use 24 TPI:
- Cutting sheet metal (20 gauge and thinner)
- Cutting small diameter rod (under 1/4 inch)
- Cutting very thin-wall tubing
- When you need the cleanest possible cut on thin material
When not to use 24 TPI:
- Material over 1/4 inch thick where the fine teeth will burn and load up
- Production cutting where the fine teeth dull too quickly
Tooth Profile
All 35-3/8 inch Milwaukee blades use a standard tooth profile with a 0 degree rake angle. The teeth are straight up, which provides a good balance of cutting speed and surface finish.
The compact saws do not have the motor torque to take advantage of hook tooth (positive rake) profiles, which are used on the deep cut saws for aggressive cutting of thick material.
Blade Material: M42 Bi-Metal
All 35-3/8 inch Milwaukee blades are bi-metal with an M42 high-speed steel edge.
M42 edge hardness: 67 to 69 HRC. Hard enough to cut mild steel, aluminum, copper, and cast iron.
Backing steel: Flexible alloy steel that withstands the flexing around the saw’s wheels.
Maximum material hardness: M42 can cut material up to about RC 38 to 40. For harder materials, you need a carbide-tipped blade, which Milwaukee does not make in this length. For carbide options, look at MK Morse or LENOX.
Cross-Brand Compatibility
The 35-3/8 inch blade is shared with:
- Milwaukee M18 FUEL Compact (2829-20)
- Milwaukee corded compact (6230-20)
- Milwaukee older M18 compact (2629-20)
- DEWALT 20V XR Mid-Size (DCS378B)
Blades from any of these brands will fit any of these saws. The blade length, width, and thickness are the same.
Alternative Blade Brands
LENOX Wolf-Band: LENOX makes 35-3/8 inch blades in 14/18 variable pitch. The variable pitch breaks up vibration and handles a range of material thicknesses. LENOX blades typically outlast Milwaukee blades by 20 to 30 percent.
MK Morse: MK Morse makes 35-3/8 inch blades in 14 and 18 TPI. The Master Cobalt blades have a more aggressive tooth geometry that cuts faster than standard bi-metal.
Starrett: Starrett makes 35-3/8 inch bi-metal blades in various TPI options. Good quality and widely available.
Blade Break-In
New Milwaukee blades need a break-in period. Run the first 10 to 20 cuts at half feed pressure. This lets the sharp tooth tips wear evenly and prevents micro-chipping. Skipping break-in can reduce blade life by 30 to 50 percent.
Blade Life Expectations
| Material | TPI | Expected Cuts per Blade |
|---|---|---|
| EMT conduit (3/4 inch) | 18 TPI | 80 to 150 |
| Thin-wall tubing (1 inch) | 18 TPI | 80 to 150 |
| Medium wall pipe (1-1/2 inch) | 14 TPI | 50 to 100 |
| Aluminum bar (1/2 inch) | 14 TPI | 80 to 150 |
| Sheet metal (20 gauge) | 24 TPI | 100 to 200 |
| Unistrut (1-5/8 inch) | 18 TPI | 60 to 120 |
FAQ
What blade does the Milwaukee M18 compact band saw use?
A 35-3/8 inch blade in 1/2 inch width and 0.020 inch thickness. Available in 14, 18, and 24 TPI.
What TPI should I use for cutting conduit?
18 TPI is the best choice for conduit. It is the general-purpose blade and handles EMT and rigid conduit cleanly.
Can I use a DEWALT 35-3/8 inch blade in my Milwaukee compact saw?
Yes. The blade length, width, and thickness are the same. DEWALT and Milwaukee 35-3/8 inch blades are interchangeable.
What is the difference between 14, 18, and 24 TPI?
14 TPI is for thicker material (1/4 to 1 inch). 18 TPI is the general-purpose choice for most work. 24 TPI is for very thin material (under 1/4 inch).
How often should I replace my 35-3/8 inch blade?
When the cut slows down, the blade starts wandering, or the cut surface becomes rough. A sharp blade cuts smoothly with light pressure.
Are LENOX blades better than Milwaukee for the 35-3/8 inch length?
LENOX Wolf-Band blades typically outlast Milwaukee blades by 20 to 30 percent. The variable pitch (14/18) is a good choice for mixed work. Both are good quality.
References
- Milwaukee Tool. “M18 FUEL Compact Band Saw Owner’s Manual.” Model 2829-20.
- Milwaukee Tool. “Portable Band Saw Blade Specifications.” Milwaukee Tool Product Catalog.
- LENOX Tools. “Wolf-Band 35-3/8 Inch Blade Guide.” LENOX Industrial Division.
- MK Morse. “Portable Band Saw Blade Comparison.” MK Morse Company.
- Starrett. “Bi-Metal Blade Specifications.” L.S. Starrett Company.
