Best way to cut aluminium tubing

[Ralphmp]

I have some small bore aluminium tubing I want to cut into shortish lengths. It's quite thin-walled and my attempts so far have led to the tube being squashed where I've cut it (I used a junior hacksaw).

Can anyone suggest a way of cutting the tube without squashing occurring?

Thanks

 

[trammayo]

I have some small bore aluminium tubing I want to cut into shortish lengths. It's quite thin-walled and my attempts so far have led to the tube being squashed where I've cut it (I used a junior hacksaw).

Can anyone suggest a way of cutting the tube without squashing occurring?

Thanks

The only thing I can think of would be a Dremel type tool with a cutting disc. I know that aluminium clogs up grinding discs (it is used in safes to prevent thieves cutting through!) but it should be a OK with disc less than a millimetre thick.

 

[playmofire]

One way would be a pipe cutter (presumably a miniature one in view of the size), but even then, in view of the thin walls, squashing might occur.

Faced with this problem, I have found that finding a rod which will just fit inside the tube or inserting a piece of brass tube inside it solves the problem.

 

[Walts-Playmobil]

You could fill it with sand

 

[Ralphmp]

Thanks for the suggestions. I'll try them out in the morning and let you know how I get on.

 

[Greg Elmassian]

the dremel with the carbide cutoff wheel, run at a slower speed will give you surgical control.

This is a must-have tool.

Greg

 

[royale]

A miniature pipe cutter would be the best bet and give you a very neat and even cut - start off with very gentle pressure and increase it as you turn it to cut. I have one that will cut down to 1/8 th inch outside diameter and it works a treat every time.

 

[minimans]

as above small pipe rotary disc pipe cutter. any big box store should have them in various sizes........

 

[dunnyrail]

A lot of the problem with cutting small pipe with a razor saw is that of holding it whilst cutting. I made up a small jig for just such jobs, consists of some small dia Brass soldered to a piece of Brass plate. I saw a gap in the tube and then you have a holder to help. Just saw slowly and gently and the razor saw should do its job.

This jig was made to cut lots of same size pieces of tube, hence the bent up end stop. But I think you will get the concept.
JonD

 

[playmofire]

A very neat and practical idea.