Contractor Converts Milwaukee Hackzall into Portable Ethernet Untwister for Massive Cat6 Job

Why a custom untwister matters

Installing RJ45 connectors on thousands of Ethernet cables is a labor intensive task. Each connector requires the individual pairs to be untwisted to the correct length, a step that is often performed with a small hand tool. When a contractor was asked to produce 50,000 custom Cat6 cables for a corporate campus, the standard hand tool became a bottleneck.

The challenge of 50,000 Cat6 cables

The project demanded consistent pair separation, precise length control and rapid turnover. Traditional untwisters can handle a few cables per minute, but the scale of the job required a tool that could double that rate without sacrificing quality. The contractor, who has worked on large data center deployments for over a decade, decided to engineer a solution that could be carried in a tool belt and used on site.

The Hackzall hack: From cutting tool to cable tool

Milwaukee’s Hackzall is a well known rotary cutting tool designed for metal and plastic. Its ergonomic grip, variable speed trigger and compact size make it a favorite among tradespeople. By repurposing the Hackzall’s motor and adding a custom attachment, the contractor created a portable Ethernet untwister that fits in a standard tool bag.

Design modifications

Removed the original cutting wheel and installed a small, precision geared spindle.
Mounted a pair of micro‑adjustable jaws that grip the outer jacket of a Cat6 cable.
Integrated a depth stop that limits how far the pairs are pulled apart, ensuring compliance with Fluke Networks cable standards.
Connected the motor to a low‑voltage battery pack for up to eight hours of continuous use.

The resulting device retains the Hackzall’s variable speed control, allowing the user to set a gentle rotation for delicate untwisting or a higher speed for tougher bundles.

Testing and performance

Initial field tests compared the new untwister with a conventional hand tool on a sample of 200 cables. The average time per cable dropped from 45 seconds to 22 seconds, a reduction of roughly 50 percent. Moreover, the tool produced consistent untwist lengths that passed the IEEE specifications for Category 6 performance.

Impact on installation workflow

When the contractor deployed the portable untwister across the full 50,000 cable order, the time savings translated into a two week reduction in overall project schedule. This accelerated timeline allowed the client to occupy the new office space earlier than planned, generating additional revenue.

Time savings

Standard hand tool: 45 seconds per cable.
Portable Hackzall untwister: 22 seconds per cable.
Total time saved: approximately 400 hours.

Cost considerations

The initial cost of the modified Hackzall was roughly $150 for the base tool plus $80 for the custom attachment. Compared with the labor cost of an extra crew member for the duration of the project, the investment paid for itself within the first few thousand cables.

Safety and compliance

Any tool that modifies electrical cabling must adhere to safety standards. The contractor consulted the OSHA safety guidelines to ensure the device did not introduce pinch points or electrical hazards. The battery pack is isolated from the cable path, and the jaws are coated with a non‑conductive polymer.

Electrical standards

By maintaining the prescribed untwist length, the tool helps preserve the cable’s impedance characteristics, a key factor for reliable high speed networking. Compliance with the CableOrganizer.com trade guide was verified through third party testing.

Adoption by contractors

Since the first deployment, other electrical contractors have expressed interest in the portable untwister. Feedback highlights the tool’s ease of use, low maintenance and the ability to carry it alongside other standard hand tools.

Feedback from the field

One installer noted, "The tool feels like a natural extension of the Hackzall I already own. I can switch from cutting metal to untwisting cable without changing equipment." Another manager reported that the reduced installation time allowed his crew to focus on testing and certification, improving overall project quality.

Future developments

The contractor plans to refine the attachment by adding a digital readout that displays the exact untwist length for each cable. Integration with a mobile app could log each cable’s specifications, creating an audit trail for large scale deployments.

As data centers and smart building projects continue to demand higher volumes of high performance cabling, tools that streamline the physical layer installation will become increasingly valuable. The Hackzall based untwister demonstrates how a simple adaptation of an existing tool can meet that demand without requiring a completely new product line.