How to Cut Pallets with a Reciprocating Saw

How to Cut Pallets with a Reciprocating Saw (Sawzall Guide for DIY Enthusiasts & Pros)

Wondering how to break wooden pallets down without ruining the boards – or worse, your back? You’re not alone. DIY fans and pro contractors use pallets for many projects. They create rustic furniture and prepare firewood, among other things.

We suggest using a reciprocating saw for safe, efficient cuts in wooden pallets. This power tool causes less damage to wood than crowbars and saws. Just pick the right blade and follow our safety tips.

In this guide, we’ll show how a reciprocating saw, or Sawzall can quickly cut pallets. Master the right blades and safety tips for the powerful Sawzall with our expert advice.

Why a Reciprocating Saw Excels at Cutting Pallets

If you’ve ever tried prying a pallet apart with a crowbar, you’ll know how tedious (and sometimes painful) it can be. That’s exactly where a reciprocating saw shines.

Less Labor, More Results

Instead of pushing boards loose with brute force, a reciprocating saw moves back and forth at high speeds. This enables you to cut through wood and nails in seconds. A Sawzall is energy efficient. It turns noise and heat into kinetic energy. This boosts cutting power and lessens physical effort. You’ll save time and energy, and your boards will stay in better condition.

Fewer Broken Boards

Crowbars and hammers can cause boards to crack or split. Using a reciprocating saw blade that’s designed for nail-embedded wood often spares the pallet slats from damage. You end up with more usable lumber, which is ideal if you’re crafting DIY furniture or selling reclaimed wood.

Versatility Beyond Pallets

Sawzalls are convenient and are well-known among the DIY community as the ideal all-rounder for all kinds of projects. You’re not just buying a niche tool. You’re investing in something versatile for many needs.

Picking the Perfect Blade for Pallet Dismantling

Choosing a saw blade is just as important as picking the initial power tool. Always choose a bi-metal or carbide-tipped reciprocating saw blade. It should cut through nails and wood while staying strong.

Key Features of a Good Pallet-Cutting Blade

Bi-Metal or Carbide-Tipped Construction

These blades are better equipped to handle embedded nails and miscellaneous fasteners. If you use a standard blade on pallet nails, it’s likely to dull or prematurely bend.

Teeth Per Inch (TPI) Range

How does TPI influence your choice of blade? Learn about saw blade TPI and your options below:

• 6-10 TPI: Perfect for quick, rough cuts. Ideal if you want to rip apart pallets fast and aren’t overly concerned with a flawless finish.
• 10-14 TPI: Balances speed with smoother cuts, making it a great all-purpose option for wood and nails.
• 14+ TPI: Produces cleaner edges but cuts at a slower rate. This can be a solid choice for reclaimed wood projects where appearance matters.

Blade Length Options

Blades come in different lengths, usually 6 to 12 inches. A longer blade makes it easier to handle pallet stringers and boards. It gives you a better reach and more flexibility in tight spots or when working overhead.

Best Sawzall Blades for Cutting Pallets

Looking for the best reciprocating saw blades? Choose one that suits your project and budget requirements. Durable carbide-tipped blades work well for businesses that reshape and sell pallet furniture.

Here are our top picks for Sawzall blades:

• Diablo Demo Demon: These are built for demolition. The bi-metal blades are great at cutting wood, nails, screws, and other debris commonly found in pallets.
• Milwaukee Torch with Carbide Teeth: If you want durability, carbide teeth are tough. They can endure many demolition sessions before showing wear.
• DeWalt Reciprocating Saw Blades: A budget-friendly yet reliable option. These may not last as long as carbide-tipped saws. However, they are perfect for casual DIYers or tradespeople who work with pallets now and then.

Step-by-Step: How to Cut a Pallet with a Reciprocating Saw

Read any DIY forum about cutting pallets, and you’ll find plenty of recip saw fans. The Screwfix community rates reciprocating saws highly for cutting wooden pallets. They are also known for being reliable. 

Now that you’ve confirmed your saw choice, we’ll show you how to use a reciprocating saw to turn pallets into neat, salvageable timber.

Step 1: Gather Your Tools & Safety Gear

What tools do you need to cut pallets? Use our checklist below:

1. Reciprocating Saw (Sawzall): Make sure it’s charged or plugged into a power source.
2. Suitable Blade: Attach a bi-metal or carbide-tipped blade suitable for the project at hand. We recommend a blade with 10-14 TPI if you’re dealing with lots of nails.
3. Safety Essentials: Always have gloves, protective eyewear, a dust mask, and earplugs or earmuffs ready before you work.
4. Sturdy Work Surface: Sawhorses or a firm table give you the stability you need to make a straight and controlled cut.

Step 2: Stabilize the Pallet

Put the pallet on top of your sawhorses or another flat surface so it doesn’t wobble. You might need to use clamps to hold everything in place. 

If you’re outdoors, you can also stand on one side of the pallet while cutting to prevent movement (just be extra mindful of your food placement).

Step 3: Pinpoint Your Cutting Lines

Inspect the pallet for screws and knots. Identify areas where you can make straight cuts without hitting too many troublesome spots. Always try to do the following:

• Aim for Nail Joints: Cutting where boards meet the stringers can produce the longest possible slats.
• Avoid Large Knots: Wood knots can cause extra friction and bend blade tips.
• Edge-to-Center Approach: Start dismantling from the outside edges before moving toward the core of the pallet.

A little planning goes a long way when you want to salvage as much usable wood as possible.

Step 4: Execute the Cut with Proper Technique

When you’re ready to cut:

1. Secure the Grip: Hold the Sawzall firmly with both hands. This helps counteract the vibrations.
2. Switch on Orbital or Pendulum Mode (If Required): If your saw has an orbital feature, use it for a faster cut through wood. The blade moves in a slight jigsaw path, which enlarges the surface area of contact.
3. Moderate Pressure: Instead of forcing the tool, let the blade do the heavy lifting. Overly aggressive pushing can jam or warp it, so only apply moderate pressure.
4. Pace Yourself: Start slower to get a feel for the resistance. Once you’re in the groove, you can increase the speed slightly.

Keep an eye on how the wood responds. If you sense too much resistance, back off and re-evaluate – you might be hitting a large nail or misaligned board.

Step 5: Detach the Boards

Once the outside cuts are made, take off the freed boards. If they’re still attached by stubborn nails, you can loosen them with a pry bar or claw hammer.

Then, continue inward by moving systematically from the pallet’s edges to its center. This keeps the entire structure stable as you work, reducing the chance of the boards snapping under their own weight.

Afterward, sweep away any leftover splinters or bent nails. Working in a clutter-free area makes it easier to see your next cut and increases your safety. Repeat the process until the pallet is entirely dismantled. You’ll be surprised by how many boards you can get out of a single pallet if you remove them cleanly!

Sawzall Cutting Techniques for Other Applications

The versatility of reciprocating saws is legendary in the trade industry. You can use reciprocating saws for many tasks. Along with cutting pallets with Sawzalls, you can also trim branches, cut metal, remove drywall, and carve sculptures.

Demolition Duties

A reciprocating saw that’s equipped with a bi-metal blade is well-equipped for demolition tasks like:

• Tearing Down Drywall
• Cutting Through Metal Studs
• Slicing Old Nails

Its advanced portability and efficiency make it the ideal choice for removing hard debris like masonry and metal. 

Other power tools, such as demolition hammers, are also suited to these jobs. However, unless you already own one, you shouldn’t go out and buy one when a Sawzall can do the trick.

Branch and Limb Trimming

If you have small branches to remove (think yard cleanup or general landscaping), a reciprocating saw can help, especially if you don’t own a chainsaw. Swap in a coarse-tooth blade suited for green wood, and you’re all set.

Metal Cutting

Need to cut steel pipes or aluminum rods? Grab a higher TPI blade specifically designed for metal – around 14-32 TPI. Make sure you keep the workpiece stable and move the saw steadily so you can avoid excessive sparks or any jagged edges.

Essential Safety Reminders

Operating a tool as powerful as a reciprocating saw calls for careful attention to safety. Please always adhere to these safety precautions:

1. Protect Your Eyes: Wood chips and metal fragments can seriously injure you when they fly around, so goggles or safety glasses are a must.
2. Guard Your Hands: Anti-vibration gloves give you a lot more comfort when you’re doing a longer project. They also give you some protection if the blade kicks back.
3. Maintain a Two-Handed Grip: Even if you feel confident, controlling the saw with both hands means you minimize any sudden jerks.
4. Don’t Force the Blade: If it’s stuck, switch it off and reset it. Continuing to push a jammed blade can twist or snap it.
5. Unplug or Remove the Battery When Changing Blades: A simple but crucial step to prevent accidental starts.

Following these tips will reduce your risk of injury and help your equipment last longer.

Frequently Asked Questions

Could I use a jigsaw or circular saw instead?

You can, but reciprocating saws are better suited for fast demolition and nail-embedded wood. Jigsaws tend to struggle with nails, and circular saws would be overkill and far harder to maneuver around pallet edges.

What’s the best Sawzall blade for cutting through nails and wood?

A bi-metal or carbide-tipped blade in the 10-14 TPI range is your safest bet. Check out brands like Diablo or Milwaukee. They focus on demolition and multi-material capabilities.

How do I prevent splintering when cutting pallets?

Splintering is common when cutting pallets with Sawzall tools. However, there are several steps you can take to mitigate this:

• Use a blade with more teeth per inch (around 10-14 TPI).
• Cut at a controlled pace.
• Support the wood from underneath to reduce vibration.

Is a reciprocating saw good for chopping firewood?

It can handle small logs or branches, especially if you’re using a more coarse blade. However, a dedicated chainsaw is usually more efficient and time-saving for bigger chunks of firewood.

How should I maintain my Sawzall blades?

Wipe them down post-use to remove sawdust and resin. If you see any surface rust, gently buff it off with steel wool. Store blades in a case or wrap to keep them dry and protect the teeth from accidental damage.

Recommended Reciprocating Saws for Pallet Dismantling

You don’t necessarily need the most expensive model to see good results, but certain brands are worth their prices. If you’re looking to cut pallets with reciprocating saws, we recommend these models:

Milwaukee M18 Fuel Sawzall (Cordless, high power)

• Cordless Convenience: Powered by an 18V battery, ideal for outdoor or remote job sites.
• Durable Construction: Holds up under repeated stress, great for frequent pallet work.
• CoOrbital Action: Allows you to toggle between straight and elliptical blade movement.

DeWalt DCS367B Reciprocating Saw (Compact, lightweight)

• Compact & Maneuverable: Its short body design makes it easier to navigate tight angles.
• Variable Speed: This lets you adapt your cutting approach based on the material.
• Ergonomic Grip: Reduces fatigue over long sessions.

Makita XRJ05Z 18V LXT (Best for long battery life)

• Impressive Battery Life: Makita’s LXT batteries hold a charge well, which is perfect for big jobs.
• Tool-Less Blade Change: Quick blade swaps if you need different TPIs for various cuts.
• Smooth Operation: Engineered to reduce vibration so you can maintain better control.

These models, when matched with the right blade, can quickly break down pallets. This results in cleaner, usable boards.

Transform Your Pallet Projects with a Reciprocating Saw

By now, you’ve seen just how easy pallet dismantling can be when you have the right setup. A reciprocating saw helps you prevent splits and splinters while sidestepping the labor of prying with hand tools. 

Pick a bi-metal or carbide-tipped blade. It can handle nail-embedded wood and cut through wooden pallets easily. You’ll soon reap the benefits of reclaimed materials for all sorts of creative endeavors.

Tired of wasting boards or fighting with a crowbar? Switching to a Sawzall can change your DIY or professional work for the better.

Just remember the key steps:

• Plan Your Cuts
• Stay Safe with Proper Gear
• Let the Blade Do the Hard Work

Looking for High-Quality Diamond Tools and Cutting Solutions?

With over 20 years of experience in the diamond tool industry, Johnson Tools has your back. We’re committed to leading the way in innovative cutting solutions. From dismantling pallets to larger-scale constructions, we’ve got the products to meet your demands. Get in touch today to see how we can help.