Cutting Aluminum Tubing

[Capt_Taggert]

I've got some small aluminum tubing and I'm not sure how to cut it, any suggestions?

 

[TiM]

How small?

down to 3mm you could use a miniature plumber's pipe cutter, the type with rollers and a cutting wheel.
below that, either a very fine saw or use a sturdy blade, like a Stanley, and carefully 'roll' it on a cutting mat to score round the pipe. It is so soft that this method works like the pipe cutter and gives a burr free edge.

Note if you chose a saw - the TPI needs to be so fine that the teeth don't engage on the diameter as such otherwise it will just drag the pipe and bounce rather than cutting. Personally, I use Zona saws at 0,010 blade thickness and down to ~52 TPI with a pull cut can't be beaten.

Finally, you could also use a miniture slitting disc in a rotary tool... ;D

 

[Capt_Taggert]

Thanks for the tips. Can't remember off hand how small, but i'll give you're suggestions a go.

 

[Grendels]

I use a small chop saw I purchased at Harbor Freight tools. Works pretty well, and it will let you adjust the angle of the cut.

 

[Ziz]

Grendels - you mean this one?

http://www.harborfreight.com/bench-top-cut-off-saw-42307.html

I made a couple of accessories for mine. One for double checking the correct angle as the holder it comes with isn't exactly perfect...

And another one for doing straight cuts of larger stock...

Made from heavy styrene sheet - about 1/8" or so - with pegs below made of bits of sprue in the right places to fit into the holes in the chop saw's base.

 

[Grendels]

That is the exact one I have. Minus the mods of course. Nice idea on those mods, I will have to study those later......