DEWALT 60V Cordless Reciprocating Saw for HVAC Pipe and Duct Work

Description

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If you’ve ever wrestled with cutting through 4-inch steel HVAC ductwork or slicing through galvanized pipes in tight mechanical rooms, you know that underpowered reciprocating saws don’t just slow you down—they cost you money. We brought the DEWALT DCS389B FLEXVOLT 60V reciprocating saw onto active job sites specifically to see if this cordless beast could handle the demanding cuts HVAC professionals face daily, from demolition work to precision pipe modifications.

After putting this tool through weeks of real-world testing on commercial HVAC installations and residential retrofit projects, we can confidently say this isn’t your typical battery-powered saw. The FLEXVOLT technology automatically adjusts voltage when you swap battery packs, delivering corded power without dragging extension cords through equipment rooms. But the question remains: does it justify the investment for HVAC work, or are you better off with a corded alternative?

Here’s what we discovered after cutting through everything from 6-inch cast iron drain lines to metal studs during ductwork installations.

Why the DEWALT DCS389B FLEXVOLT 60V Reciprocating Saw Stands Out

The most impressive feature we noticed immediately was the variable speed trigger with four-position blade clamp. Unlike standard reciprocating saws that force you into awkward angles, this saw let us rotate the blade to access tight spaces around existing ductwork and piping—a game-changer when working in cramped mechanical rooms or attic installations.

What genuinely surprised us was the runtime. Using a FLEXVOLT 60V battery, we made over 200 cuts through 3-inch galvanized duct before needing a recharge. That’s a full day’s worth of demo work on most residential HVAC replacement jobs. Compare that to the 20V models we’ve tested that barely made it through half a job before demanding a battery swap.

The 1-1/8 inch stroke length generates aggressive cutting action that powers through materials faster than competitive models in this class. We clocked cutting times on 4-inch PVC drain lines at roughly 8 seconds per cut—nearly identical to our corded Milwaukee that usually lives in the van. For HVAC techs who’ve tolerated sluggish cordless performance for years, this speed difference is immediately noticeable.

Perhaps most importantly for HVAC applications, the tool-free blade changes actually work under real job conditions. Even with gloves on and your hands covered in duct sealant, the lever-action blade release lets you swap blades in seconds. We’ve used “tool-free” systems that jam or require pliers to operate, but DEWALT engineered this one properly.

Key Features & Specifications

• Voltage: 60V MAX (54V nominal) with FLEXVOLT technology that automatically adjusts to 20V MAX when using 20V batteries—ideal for techs already invested in DEWALT’s 20V system
• Stroke Length: 1-1/8 inches—longer than most cordless models, translating to faster cuts through thick materials like cast iron or bundled copper lines
• Strokes Per Minute: 0-3,000 SPM variable speed—full control from delicate finish cuts on exposed ductwork to aggressive demo work
• Blade Clamp: 4-position (0°, 90°, 180°, 270°)—eliminates the need to contort yourself around mechanical equipment or ceiling joists
• Weight: 8.7 lbs (tool only)—noticeably heavier than 20V models but balanced well enough for overhead cuts
• Shoe: Pivoting, adjustable for depth control—extends blade life by distributing wear and provides stability on round pipe
• LED Work Light: Integrated with 20-second delay—genuinely useful in attics and crawl spaces, not just a gimmick

Note: This is a bare tool only (DCS389B). You’ll need to purchase FLEXVOLT 60V batteries and charger separately. If you’re already running DEWALT 20V tools, your existing batteries will work but won’t deliver the full 60V performance.

Hands-On Performance Testing

We put the DCS389B through three specific HVAC scenarios to evaluate real-world performance where it matters most.

Ductwork Demolition and Modification: During a commercial rooftop unit replacement, we needed to remove and modify approximately 40 linear feet of 6-inch galvanized ductwork. Using a 9-inch metal cutting blade, the saw powered through 22-gauge galvanized steel without bogging down or creating excessive vibration. The pivoting shoe kept the blade stable against the round duct surface, preventing the blade walk that usually chews through blades prematurely. We completed the entire demo on a single 9.0Ah FLEXVOLT battery with power to spare.

Copper Line Set Cutting: When retrofitting a mini-split system in an older home, we needed to cut through existing 3/4-inch copper refrigerant lines in a tight wall cavity. The variable speed trigger gave us precise control to start cuts without blade chatter, and the 90-degree blade position let us work flush against a stud that would’ve been impossible with a fixed-blade saw. Clean cuts every time with minimal burr formation.

PVC and Cast Iron Drain Work: HVAC condensate drain installations often require cutting PVC in finished spaces where you can’t afford mistakes. The saw’s balance and trigger control allowed accurate cuts without the jerky starts we’ve experienced with other cordless models. We also tested it on a 4-inch cast iron drain stack during a furnace replacement—it chewed through in about 15 seconds, though we noticed more vibration on cast iron compared to lighter materials.

One unexpected benefit: the LED light positioned near the blade actually illuminates your cut line in dark spaces. We’re usually skeptical of “work lights” on power tools, but this one proved genuinely helpful when working in unlit attic spaces or behind mechanical equipment.

The saw did heat up noticeably during extended use, particularly when making multiple cuts through thick steel. After about 30 continuous cuts, the motor housing was quite warm to the touch, though it never triggered any thermal shutdown. We started spacing out our cuts slightly during marathon demo sessions, which is probably wise for tool longevity anyway.

What We Liked (Pros)

• Legitimate corded performance without the cord: This isn’t marketing exaggeration—the 60V power delivery genuinely matches corded models we’ve used for years, finally making cordless viable for demanding HVAC demolition work
• Four-position blade clamp solves real problems: Not just a convenience feature, this completely changed how we approach cuts in confined mechanical rooms and around existing equipment installations
• Outstanding battery runtime for professional use: A single 9.0Ah FLEXVOLT battery lasted through what previously required two or three battery changes with 20V saws, meaning less downtime and fewer batteries to manage on the truck
• Tool-free blade changes that actually work: The lever system operates smoothly even in less-than-ideal conditions, and the blade stays locked securely during aggressive cutting
• Excellent balance and control: Despite the weight, the saw feels stable during overhead cuts and precision work—the weight distribution clearly received engineering attention rather than being an afterthought

What Could Be Better (Cons)

• Significant upfront investment for bare tool: At the current price point, you’re looking at substantial cost before adding required batteries and charger. If you’re not already in the DEWALT ecosystem, the total system investment approaches $500+, which is difficult to justify unless you’re doing regular demo work
• Weight becomes fatiguing