Nothing slows down a lighting install like a messy corner cut.
Whether you’re working on fascia tracks or creating tight roofline angles, clean cuts make the difference between a good job and a professional one. While corner pieces can simplify many installs, knowing how to make these cuts by hand gives you flexibility, precision, and control on any job site.
Table of Contents
- The Basic Cut
- Creating a 90° Corner
- Perfecting Fascia Track Cuts
- Handling Outside Corners
- Tackling Tricky Angles
- Wrapping Up: Why Precision Matters
1. The Basic Cut
Every installer should master the basic hat track cut.
Start by marking your cut line, then make two relief cuts on the flanges—this allows your shears to move freely for the vertical cut. Use the right tool for the side you’re keeping: red shears for the left, green shears for the right. This prevents warping and ensures a clean edge. Use your thumb to break the last edge where you want it to snap cleanly.
💡 Pro Tip: Big Star’s Ultimate Wire Cutters make precise, smooth cuts that won’t fray metal or paint.
2. Creating a 90° Corner
There are two ways to make a perfect 90° corner:
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Method 1: Cut out a small section of the track so one piece nests inside the other. This creates a seamless joint with no visible gaps. Use linesman pliers with tape on the jaws to protect the finish.
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Method 2: Cut two 45° angles—one slightly offset by ¼ inch. This offset creates a small tab that hides any gaps once the pieces are joined. The result? A tight, polished look that stands up under close inspection.
3. Perfecting Fascia Track Cuts
For inside corners, mark your angle lines and identify the lip that needs to be removed so tracks can nest properly. Cut, bend, and snap off excess with your pliers. If the bulb ridge prevents a snug fit, simply crush it down gently for a flush joint.
When working on outside corners, only one track typically needs to be cut. Mark your triangle and back surface cuts carefully, then remove the interior lip for nesting. If needed, trim the bottom surface slightly, leaving a ¼-inch tab to cover small gaps. A little patience here ensures a crisp, professional exterior line.
5. Tackling Tricky Angles
For obtuse (150°) or acute angles, use a speed square to calculate your cut—subtract your desired angle from 180° to find your mark. Offset by ¼ inch to form a cover tab, make relief cuts, and trim corners for a snug fit. This method works beautifully for custom peaks and roof transitions.
6. Wrapping Up: Why Precision Matters
Sharp, accurate cuts don’t just make your work look great—they save time, reduce call-backs, and make every installation faster and more profitable.
At Big Star Lights, our team of former installers has designed tools and tracks specifically for efficiency and precision. When your tools work as hard as you do, every cut looks clean, and every client is impressed.
Explore more installer tools on our Pro Tools Collection.
Frequently Asked Questions
Q: Can I avoid these cuts with pre-made corners?
A: Yes, but knowing how to make custom cuts ensures flexibility on-site—especially for unique rooflines.
Q: Which shears should I use?
A: Use red shears for left-side cuts and green for right-side cuts to avoid bending the edges.
Q: How can I protect paint on the tracks?
A: Wrap your plier jaws with tape before bending or snapping metal.
Summary
- Master basic, 90°, and fascia cuts for professional results.
- Use color-coded shears correctly to avoid edge damage.
- Create offset tabs for gap-free joints.
- Crush bulb ridges for tighter fascia fits.
- Precision saves time, prevents rework, and impresses clients.