Cutting Aluminum Shafts

[bunyan]

How do you guys (and Gals) go about cutting your aluminum?  Are you using one of the expensive power cutters?  One of the hand cutters sold by 3Rs and the rest?  Something from the Hardware store?  How are you doing at keeping the cut square?  I'm putting together my first set of aluminums and want to know what route I should take.  Do I need one of those deburring tools or "squaring" tools sold by the shops?  Thanks for the input!

[Talondale]

Check out this post I made:
 http://tradgang.com/cgi-bin/ultimatebb.cgi?ubb=get_topic;f=1;t=048078

I found the pipecutter worked fine and I didn't have to do much to get inserts to fit.

[Wary Buck]

I've used a cheap pipe-cutter (time consuming) and then chamfer the inside of the shaft to accept the insert by using a very large three-blade Snuffer head to scrape out a slight bevel.  Cheap man's route, but it's worked for me.

[Flints]

I bought a micro-tubing cutter that works well, slow but well.A few seconds using a tapered round file cleans up the cut end.Not for high volume use but easy to do. I haven't had any problems with keeping the cut end square.Good luck.

[Murph From The Bay]

I agree with the pipe cutter - certainly easiest and cheapest.  Seems to work well with mine.

[Jim Harris]

I have used a mini tube cutter for many years on Aluminum shafts. Works fine, just go a little at a time on the cut so you don't crush the shaft at the cut. I have also used a tool from Lyman to smooth up the end of the shafts. I am not sure if it is still available. The tube cutter cuts the shafts square but leaves them a little rough and the Lyman tool smooths this up. Then I use a cartridge case deburr tool to deburr the inside and outside. Just deburr a little to take edge off. Jim

[Aggie1993]

Used a Dremel Tool when I used to shoot aluminums.

[Rick_H]

I use a dremel tool also....If you do a search on this forum you can find a thread with lots of posts with tips about using a dremel.

[bunyan]

Thanks for the input guys!

[dachba]

The power tools aren't really that expensive.  I bought a mini-cutoff saw from Harbor Freight several years ago.  At the time I paid about $19.  I think they are currently selling on sale for $19.99.  I cut aluminums and carbons with it.

I imagine they will also cut woods with no problem.

This is the Harbor Freight part#: ITEM 42307-3VGA
Dave in Ft. Collins, CO