Portable Band Saw Blades: Dimensions, Uses, and Selection Rules
You need a blade for your portable band saw and you want to know which one to buy. Portable band saws use several blade lengths depending on the brand and model. You need to know the correct blade length, width, TPI, and material for your saw.
Portable band saw blades are the blades used in portable band saws, which are handheld band saws designed for cutting metal pipe, conduit, unistrut, and bar stock. Portable band saws are made by Milwaukee, DEWALT, Makita, Porter Cable, and others, and each model requires 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 Brand and Model
Milwaukee
| Model | Type | Blade Length | Cut Capacity |
|---|---|---|---|
| 2729-20, 2929-20 | M18 FUEL deep cut | 44-7/8 inches | 5 x 5 inches |
| 6232-20, 6238-20 | Corded deep cut | 44-7/8 inches | 4-3/4 x 4-3/4 inches |
| 2629-20, 2829-20 | M18 FUEL compact | 35-3/8 inches | 2-1/2 x 2-1/2 inches |
| 2429-20 | M18 compact (older) | 32-7/8 inches | 2-1/2 x 2-1/2 inches |
| 2529-20 | M12 FUEL sub-compact | 30-9/16 inches | 1-3/4 x 1-3/4 inches |
DEWALT
| Model | Type | Blade Length | Cut Capacity |
|---|---|---|---|
| DCS374B, DCS375B | 20V MAX XR deep cut | 44-7/8 inches | 5 x 5 inches |
| DCS376B | 20V MAX XR deep cut (variable speed) | 44-7/8 inches | 5 x 5 inches |
| DCS371 | 20V MAX compact | 32-7/8 inches | 2-1/2 x 2-1/2 inches |
| DCS368 | 20V MAX Atomic compact | 32-7/8 inches | 2-1/2 x 2-1/2 inches |
| DWM120, DWM120K | Corded deep cut | 44-7/8 inches | 4-3/4 x 4-3/4 inches |
Makita
| Model | Type | Blade Length | Cut Capacity |
|---|---|---|---|
| XBP02TX, XBP02Z | 18V LXT deep cut | 44-7/8 inches | 4-3/4 x 4-3/4 inches |
| BPB180 | 18V LXT compact | 32-7/8 inches | 2-1/2 x 2-1/2 inches |
| 2107FK | Corded compact | 32-7/8 inches (verify) | 2-1/2 x 2-1/2 inches |
| LB1200F | 18V LXT compact | 32-7/8 inches (verify) | 2-1/2 x 2-1/2 inches |
Other Brands
| Brand | Model | Blade Length | Notes |
|---|---|---|---|
| Porter Cable | PCE4530 | 44-7/8 inches (verify) | Deep cut |
| BLACK+DECKER | 9411 | 44-7/8 inches (verify) | Deep cut |
| Bauer | PBLBCS20 | 32-7/8 inches (verify) | Compact |
Standard Blade Dimensions
All portable band saw blades share these dimensions:
| Dimension | Value |
|---|---|
| Width | 1/2 inch |
| Thickness | 0.020 inches |
The only difference between models is the blade length.
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 5 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 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. 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 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.
How to Determine Your Blade Size
Method 1: Check the Manual
The owner’s manual lists the correct blade length.
Method 2: Measure the Old Blade
If you have the old blade, measure its total circumference. This is the blade length.
Method 3: Check the Model Number
Find the model number on the saw and look it up in the tables above.
Method 4: Contact the Manufacturer
Call the manufacturer’s customer service with the model number.
FAQ
What size blade does my portable band saw use?
Check the tables above for your brand and model. All portable band saw blades are 1/2 inch wide and 0.020 inch thick. The blade length varies by model: 44-7/8, 35-3/8, 32-7/8, or 30-9/16 inches.
What TPI should I use for my 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 portable band saw blades interchangeable between brands?
Yes, if the blade length matches. A 44-7/8 inch blade fits Milwaukee, DEWALT, and Makita deep cut saws. A 32-7/8 inch blade fits Milwaukee, DEWALT, and Makita compact saws.
References
- Milwaukee Tool. “Portable Band Saw Blade Guide.” Milwaukee Tool.
- DEWALT. “Portable Band Saw Blade Compatibility.” DEWALT Tools.
- Makita. “Portable Band Saw Blade Guide.” Makita USA.
- LENOX Tools. “Portable Band Saw Blade Specifications.” LENOX Industrial Division.
- Starrett. “Bi-Metal Blade Guide.” L.S. Starrett Company.
