Cut Pallets Easily with a Reciprocating Saw (Sawzall Guide)

Wondering how to break down wooden pallets without ruining the boards or your back? At Johnson Tools, we’ve heard this question from plenty of DIY enthusiasts and professional contractors. The good news is there’s an easier way. Instead of struggling with crowbars and hammers, the trick is to use a reciprocating saw – often called a Sawzall – to slice through pallet wood (and those pesky nails) in no time. Just make sure you’ve got the right blade and follow a few safety tips.

In this friendly Sawzall guide, we’ll show you how to cut pallets quickly and safely. You’ll learn why reciprocating saws excel for this job, how to choose the best blade, and the step-by-step process to dismantle a pallet like a pro. Let’s get started!

Why Use a Reciprocating Saw for Pallets?

Using a reciprocating saw for pallets is a game-changer. Here are a few reasons this power tool shines for pallet dismantling:

• Less Labour, More Results: Prising apart a pallet with hand tools is hard graft. A reciprocating saw’s rapid back-and-forth motion cuts through wood and nails in seconds, saving you heaps of effort. You’ll get the job done faster and with far less physical strain (your arms and back will thank you!).
• Fewer Broken Boards: Crowbars and mallets can split or crack the wood. A Sawzall fitted with the right blade zips through nails without splintering the timber. That means you end up with more usable boards – perfect if you’re crafting rustic furniture or salvaging wood for projects.
• Versatility Beyond Pallets: A reciprocating saw isn’t a one-trick pony. You’re not buying a niche tool just for pallets – you’re investing in a versatile all-rounder. From pruning tree branches to cutting plastic pipes, a Sawzall can tackle all kinds of DIY and construction tasks (more on these later). In short, you’ll get plenty of use out of it beyond just pallet work.

Choosing the Right Blade for Pallet Dismantling

The blade you use is just as important as the saw itself. For cutting pallets, you need a blade that can handle both wood and embedded nails. We recommend using a durable bi-metal or carbide-tipped reciprocating saw blade so it won’t dull or bend when it hits metal. (In fact, Johnson Tools’ reciprocating saw blades are designed for tough jobs like this.)

When picking a Sawzall blade for pallets, keep these key factors in mind:

Pick the Right Blade – Make Pallet Cutting Easy

Want to tear down pallets fast without wrecking the boards? The secret is using the right blade for your reciprocating saw!

✅ Use the Right Material: Bi-metal or Carbide-Tipped

Regular blades bend or dull quickly when they hit nails. Bi-metal or carbide-tipped blades can handle wood with nails — they’re tough, durable, and built for this job.

✅ TPI (Teeth Per Inch) – Find Your Sweet Spot:

• 6–10 TPI: Big teeth, fast cuts. Great for rough work when looks don’t matter.
• 10–14 TPI: A good mix of speed and smoothness. Perfect for most pallet jobs.
• 14+ TPI: Smaller teeth, cleaner cuts. Best when you want pretty boards for projects.

✅ Blade Length – Not Too Short, Not Too Long

A 6 to 9 inch (15–23 cm) blade works best for most pallet cuts. Longer blades can flex more, but help reach into tight corners.

Best Blades for the Job

• Diablo Demo Demon – Built for destruction. Rips through pallets, nails, and screws with ease.
• Milwaukee “Torch” Carbide – Long-lasting and nail-proof. A top pick for pros.
• DeWalt Blades – Budget-friendly, reliable for light DIY use.
• Johnson Tools Blades – Specially made for pallet cutting. Tough, affordable, and trusted by builders.
  👉 See Johnson Tools Reciprocating Blades

How to Cut a Pallet – Quick & Easy Steps

Step 1: Get Your Gear
You’ll need a reciprocating saw (Sawzall), a bi-metal or carbide blade (10–14 TPI), gloves, goggles, and a stable table or sawhorses.

Step 2: Secure the Pallet
Place the pallet on a steady surface. Clap it down or have someone hold it so it doesn’t move while cutting.

Step 3: Plan Your Cuts
Cut where the slats meet the support beams (stringers). Avoid knots and work from the edges toward the middle to keep it stable.

Step 4: Start Cutting
Hold the saw with both hands. Start slow, then speed up. Let the blade do the work—don’t force it. If you feel resistance, stop and check for big nails or metal.

Step 5: Remove the Boards
Lift off the cut boards. If some are stuck, use a hammer or pry bar. Keep going until all boards are off. You’ll end up with plenty of clean, usable wood.

Other Handy Uses for Your Reciprocating Saw

One of the best things about owning a reciprocating saw is its sheer versatility. While they’re amazing for cutting pallets, that’s just the tip of the iceberg. Here are a few other tasks where your Sawzall can come in handy:

• Quick Demolition
  Tearing out drywall or old fixtures? A reciprocating saw cuts through plaster, nails, and metal studs with no fuss. It’s compact, easy to handle, and great for renovation jobs without needing bulky tools.
• Yard Cleanup & Pruning
  No chainsaw? No problem. Pop on a coarse blade and trim small branches or shrubs with ease. It’s light, safe, and perfect for general garden work.
• Cutting Metal
  With a fine-tooth blade, a Sawzall can slice through pipes and metal rods. Just clamp things down, go slow, and let the saw do the work — way easier than a hacksaw.

As you can see, this tool is a real workhorse for all sorts of jobs. Once you’ve finished your pallet project, you’ll likely find plenty of other uses for your reciprocating saw around the workshop and home.

Essential Safety Tips

A reciprocating saw is a powerful tool, so always put safety first. Keep these essential safety tips in mind whenever you’re using a Sawzall:

• Protect Your Eyes: Always wear safety glasses or goggles. Pallet wood can produce flying chips or dust, and hitting a hidden nail could send tiny metal fragments toward your face. Eye protection is a must to prevent serious injuries.
• Guard Your Hands: Wear sturdy work gloves to get a better grip on the saw and to shield your hands from splinters or a slipping blade. Anti-vibration gloves are even better – they’ll make the sawing more comfortable during long sessions and offer extra padding if the saw kicks back unexpectedly.
• Maintain a Two-Handed Grip: Even if you’re an experienced user, don’t get complacent and try one-handed operation. Using both hands gives you maximum control over the saw’s vigorous movements and helps minimise any sudden jerks if the blade binds.
• Don’t Force a Stuck Blade: If the blade gets jammed in the wood, stop and turn off the saw before trying to free it. Never attempt to wrench a stuck blade out while the saw is running – this can easily snap the blade or cause the saw to jump. Instead, release the trigger, wait for everything to stop, then work the blade loose (you might need to wiggle the wood or back the saw out carefully). Resume cutting only when the blade moves freely again.
• Disconnect Power When Changing Blades: This is a simple but crucial rule. If you need to swap blades or do any adjustment, unplug the cord or remove the battery first. It prevents any chance of the saw accidentally turning on while your fingers are near the blade. It only takes a second and can avert a serious accident.

Following these precautions will greatly reduce the risk of injury and also help your equipment last longer. Stay safe, take your time, and respect the tool – and you’ll have a trouble-free experience.

Quick FAQ – Sawzall & Pallet Cutting

Q: Can I use a jigsaw or circular saw instead?
A: You could, but a reciprocating saw (Sawzall) is much better for pallets. Jigsaws struggle with nails, and circular saws can be hard (and dangerous) to fit into tight pallet spaces.

Q: What’s the best blade for wood with nails?
A: Use a bi-metal or carbide-tipped blade, around 10–14 TPI. It cuts through wood and nails without breaking. Brands like Johnson Tools, Diablo, and Milwaukee are great picks.

Q: How do I stop the wood from splintering?
A: Use a blade with more teeth (14 TPI), cut slowly, and support the wood so it doesn’t shake.

Q: Can I cut firewood with a Sawzall?
A: Yes, for small branches or kindling. But for big logs, a chainsaw is faster and better.

Q: How do I take care of my blades?
A: Wipe them clean after use, store them dry, and replace if they bend or get dull.

Recommended Reciprocating Saw Models for Pallet Cutting

You don’t need the most expensive saw on the market to break down pallets, but a decent-quality tool will make the job smoother. Here are a few popular reciprocating saw models that many DIYers and pros trust for pallet work:

Milwaukee M18 Fuel Sawzall
This cordless powerhouse is built tough. It cuts through pallets with ease and handles nails like a champ. Great for pros who need performance on the go.

DeWalt DCS367B
Compact and lightweight, this saw is perfect for tight spaces. It’s easy to control, making it ideal for beginners or quick DIY projects.

Makita XRJ05Z 18V LXT
Known for long battery life and smooth operation, the Makita is great for longer jobs. Blade changes are quick, and the low vibration makes cutting easier on your hands.

Any of the above saws, paired with a quality blade, will chew through pallets with ease. Of course, if you already own a corded reciprocating saw from another brand, that can work perfectly well too – no need to buy a new one just for pallets. The key is making sure your blades are up to the task and following the techniques and safety practices we discussed.

Transform Your Pallet Projects with the Right Tools

By now, you’ve seen how using a reciprocating saw can make dismantling pallets far easier and more efficient. With the right setup, you’ll avoid split wood, save a ton of time, and spare yourself the aches and pains that come from wrestling with crowbars. Just remember the key takeaways: plan your cuts, use the proper blade, wear your safety gear, and let the saw do the hard work for you.

Looking for High-Quality Diamond Tools and Cutting Solutions?

For over 20 years, Johnson Tools has been a leader in the diamond tool industry, and we’ve got your back when it comes to innovative cutting solutions. From dismantling pallets to larger-scale construction projects, we offer the products and expertise to meet your needs. If you’re gearing up for your next big project, we’re here to help – don’t hesitate to get in touch with us today and let our team assist you in finding the perfect tools for the job. Happy cutting!