Rotary Cutting Tool

Cutting Wire Shelving: A Guide for Beginners

Understanding Wire Shelving

Wire shelving offers a cost-effective solution for adding ventilated storage to various spaces. Its versatility allows for customization by cutting it to fit any desired width. The strength of wire shelving stems from its longitudinal wire splines that hold it together. These splines are typically thicker than the perpendicular cross wires, requiring special cutting tools.

Methods for Cutting Wire Shelving

Bolt Cutter

Bolt cutters are the preferred method for cutting wire shelving due to their ability to quickly snap splines. They require a minimum length of 14 inches to effectively cut the splines. Using a bolt cutter improperly can deform the wire ends, but these can be easily fixed with a metal file.

Hacksaw

Hacksaws are a convenient and reliable option for cutting wire shelving. The bi-metal blade is sufficient for cutting the splines. However, cutting with a hacksaw can be slower than using a bolt cutter, especially for shelves with multiple splines or thick splines.

Rotary Cutting Tool

A small, electric rotary tool with a metal cut-off wheel can also be used to cut wire shelving. While cuts are not as fast as with a bolt cutter, this method is suitable for those seeking a less physically demanding option. The angled cuts produced by the tool can be covered with plastic shelf end caps.

Safety Considerations

When cutting metal, always wear eye and ear protection. Sharp ends can pose a hazard during and after cutting. If an assistant is helping, ensure they remove their hands before making the cut.

Step-by-Step Instructions

Measuring and Marking

1. Measure the width of the area where the wire shelving will be installed.
2. Use an indelible marker to mark the cutting points on the wire splines.
3. Ensure that the cut points are centered between the thin perpendicular wires.
4. If the cut point falls on a thin wire, cut the shelf shorter rather than longer.

Cutting with a Bolt Cutter

1. Place the shelf on the ground facing upward.
2. Hold the bolt cutter and straddle the shelf with your shoes.
3. Open the blades and place them over the cut mark on the wire spline.
4. Close the handles in one motion.
5. Repeat until all splines have been cut.

Cutting with a Hacksaw

1. Place the shelf upside down on a table.
2. Slide the shelf so that the cut point is 2-3 inches from the table’s edge.
3. Clamp the shelf to the table.
4. Cut the spline farthest away from you.
5. Progressively cut all the splines, holding the loose end level.

Cutting with a Rotary Cutting Tool

1. Place the shelf right side up on a table covered with cardboard or scrap wood.
2. Clamp both sides of the shelf to the table.
3. Hold the tool with the cutting wheel vertical.
4. Cut the unsupported splines first.
5. Cut the splines directly contacting the work surface last, using cardboard as a buffer.

Finishing Touches

Filing Cut Ends

Remove any metal burrs or tags using a metal file. Do not over-file.

Repairing Nicked Coating

Touch up any scratches or nicks on vinyl-coated or epoxy/polyester powder-coated shelves with white appliance touch-up paint.

Installing Shelf End Caps

Fit shelf end caps onto every cut spline wire end.

Tips for Cutting and Installing Wire Shelving

• Place cut ends against the wall for partial-length shelves.
• Use a fresh cutting blade or wheel for optimal results.
• Keep the bolt cutter straight to avoid distorting the metal.
• Sharpen bolt cutter blades or use longer handles if needed.
• Use removable poster putty to secure end caps that won’t stay on.

Frequently Asked Questions

What’s the best way to cut wire shelving?

Bolt cutters are generally the best option, but hacksaws are more economical for smaller projects.

Can you cut splines flush with the cross wires?

No, leave 1/4-inch to 1/2-inch of spline protruding to maintain strength and allow for end caps.

How to fix spline end caps that fall off?

File the end gently or use removable poster putty to create friction.

Can stores cut wire shelving?

Home Depot, Lowe’s, and The Container Store offer free wire shelving cutting services.

Can you extend wire shelving that’s cut too short?

No, but additional wire shelving and wall brackets can be used to extend the length.