Milwaukee Portable Band Saw Blades: Dimensions, Uses, and Selection Rules
You own a Milwaukee portable band saw and you need to buy blades. Milwaukee portable band saws use several blade lengths depending on the model. You need to know the correct blade length, TPI, and material for your saw. You need a guide that covers Milwaukee portable band saw blades.
Milwaukee portable band saws are among the most popular portable band saws on the market. They are used for cutting metal pipe, conduit, unistrut, and bar stock. Milwaukee offers deep cut and compact models, each requiring a specific blade length.
A quality blade for Milwaukee deep cut saws is the Milwaukee 48-39-0502 Bi-Metal Band Saw Blade 44-7/8 inch 10 TPI.
Blade Lengths by Model
Deep Cut Models (44-7/8 Inch Blade)
| Model | Type | Blade Length | Cut Capacity |
|---|---|---|---|
| 2729-20 | M18 FUEL deep cut (tool only) | 44-7/8 inches | 5 x 5 inches |
| 2929-20 | M18 FUEL deep cut (newer) | 44-7/8 inches | 5 x 5 inches |
| 6232-20 | Corded deep cut | 44-7/8 inches | 4-3/4 x 4-3/4 inches |
| 6238-20 | Corded deep cut (variable speed) | 44-7/8 inches | 4-3/4 x 4-3/4 inches |
| 6230-20 | Corded deep cut (older) | 44-7/8 inches | 4-3/4 x 4-3/4 inches |
Compact Models (35-3/8 Inch Blade)
| Model | Type | Blade Length | Cut Capacity |
|---|---|---|---|
| 2629-20 | M18 FUEL compact | 35-3/8 inches | 2-1/2 x 2-1/2 inches |
| 2829-20 | M18 FUEL compact (newer) | 35-3/8 inches | 2-1/2 x 2-1/2 inches |
Sub-Compact Models (30-9/16 Inch Blade)
| Model | Type | Blade Length | Cut Capacity |
|---|---|---|---|
| 2529-20 | M12 FUEL sub-compact | 30-9/16 inches | 1-3/4 x 1-3/4 inches |
Older Compact Models (32-7/8 Inch Blade)
| Model | Type | Blade Length | Cut Capacity |
|---|---|---|---|
| 2429-20 | M18 compact (older) | 32-7/8 inches | 2-1/2 x 2-1/2 inches |
Blade Dimensions
Standard Dimensions
Width: 1/2 inch (all Milwaukee portable saws). Thickness: 0.020 inches.
TPI Selection
By Material and Thickness
| TPI | Best For | Material Thickness |
|---|---|---|
| 10 TPI | Thick pipe, solid bar | 1/4 to 2 inches |
| 14 TPI | Medium thickness | 1/8 to 1 inch |
| 18 TPI | Thin material, conduit | Under 1/4 inch |
| 10/14 variable pitch | Mixed thicknesses | All |
| 24 TPI | Very thin sheet metal | Under 1/8 inch |
Recommended TPI by Application
EMT conduit (1/2 to 1-1/2 inch): 18 TPI. Thin-wall tubing (1/2 to 1 inch): 18 TPI. Medium wall pipe (1 to 2 inches): 14 TPI. Thick wall pipe (2 to 4 inches): 10 TPI. Solid bar (1/4 to 1 inch): 14 TPI. Solid bar (1 to 2 inches): 10 TPI. Unistrut (1-5/8 inch): 18 TPI. Sheet metal (16 gauge and thinner): 24 TPI.
Blade Material
Bi-Metal M42
The standard for Milwaukee portable band saw blades. Hardness: 67 to 69 HRC. Best for: Mild steel, stainless steel, aluminum, copper. Cost: 15 to 30 dollars.
Bi-Metal M51
Harder edge for tough materials. Hardness: 69 to 70 HRC. Best for: Stainless steel, tool steel, hard alloys. Cost: 20 to 35 dollars.
Carbide-Tipped
For production cutting. Best for: High-volume cutting, abrasive materials. Cost: 40 to 80 dollars.
Tooth Profiles
Standard Tooth (0 Degree Rake)
Good balance of cutting speed and surface finish. The most common profile.
Hook Tooth (Positive Rake)
Cuts aggressively. Best for thick stock and solid bar.
Variable Pitch (Alternating Teeth)
Reduces vibration and handles mixed thicknesses. Produces smoother cuts and less noise.
Blade Life Expectations
| Material | TPI | Expected Cuts |
|---|---|---|
| EMT conduit (1/2 inch) | 18 TPI | 100 to 200 |
| Thin-wall tubing (3/4 inch) | 18 TPI | 100 to 200 |
| Medium wall pipe (1-1/2 inch) | 14 TPI | 70 to 150 |
| Thick wall pipe (3 inch) | 10 TPI | 50 to 100 |
| Solid bar (1 inch) | 14 TPI | 60 to 120 |
| Solid bar (2 inch) | 10 TPI | 40 to 80 |
| Stainless steel (1 inch) | 14 TPI | 40 to 80 |
Blade Break-In
New blades need a break-in period. Run the first 10 to 20 cuts at half feed pressure. This lets the tooth tips wear evenly and prevents chipping.
Where to Buy Milwaukee Portable Band Saw Blades
Milwaukee Tool: OEM blades in all lengths and TPI. LENOX: Wolf Band and standard bi-metal blades. Starrett: Bi-metal blades in all lengths. Olson Saw: Budget bi-metal blades. Amazon: Various brands and specifications.
FAQ
What blade does my Milwaukee portable band saw use?
Deep cut models (2729-20, 2929-20, 6232-20, 6238-20) use 44-7/8 inch blades. Compact models (2629-20, 2829-20) use 35-3/8 inch blades. Sub-compact (2529-20) uses 30-9/16 inch blades. Older compact (2429-20) uses 32-7/8 inch blades.
What TPI should I use for my Milwaukee portable band saw?
10 TPI for thick pipe and solid bar. 14 TPI for medium thickness. 18 TPI for thin material and conduit. 10/14 variable pitch for mixed thicknesses.
Are Milwaukee OEM blades better than aftermarket?
Milwaukee OEM blades are good quality. LENOX Wolf Band and Starrett blades are also excellent. For most users, any quality bi-metal M42 blade in the correct length and TPI will work well.
References
- Milwaukee Tool. “Portable Band Saw Blade Guide.” Milwaukee Tool.
- LENOX Tools. “Portable Band Saw Blade Specifications.” LENOX Industrial Division.
- Starrett. “Bi-Metal Blade Guide.” L.S. Starrett Company.
- Pro Tool Reviews. “Milwaukee Band Saw Blade Review.” ProToolReviews.com.
