Custom Tube lengths

BlackPearl · Jun 26, 2011

This is my first post at IAP so I hope I am doing correctly.

I would like to modify a kit (Deluxe Toothpick Holder) by making the tube longer to hold some special tools. What is the best way to cut a brass tube to the length that I want?

I do not want to cause an inside burr nor do I want to crush the tube.

I did a couple of searches but could not find anything about cutting tubes. I am sure I missed them cause I never do anything original.

Lenny · Jun 26, 2011

If you can buy replacement tubes for the kit you could just glue 2 tubes in. Cutting it to length by any method you want (bandsaw would work) AFTER it is glued in shouldn't be a problem as the glue will support it. Just remember to allow extra to trim back using a barrel trimmer or your methos of choice. Any burrs are easily removed with a countersink bit or special de-burrer sold by at least a couple different vendors here, (Johnnycnc and IPD_MR, I think have them at there stores).
Others have used a little motorized cut-off tool purchased at Harbor Frieght for cuttung custom tube sizes.

staushg69 · Jun 27, 2011

I use this little guy from harbor freight. Makes a nice 90 deg cut.

nava1uni · Jun 27, 2011

You can use a small hacksaw. If you cut it with support then the tube won't be marred and you can clean the inside with a tat tail file.

navycop · Jun 28, 2011

nava1uni said:
You can use a small hacksaw. If you cut it with support then the tube won't be marred and you can clean the inside with a tat tail file.

rat tail file?

refueler1 · Jun 28, 2011

staushg69 said:
I use this little guy from harbor freight. Makes a nice 90 deg cut.

Does that thing actually work. I have looked at it a few times. Does it leave a clean edge?

sbwertz · Jun 28, 2011

staushg69 said:
I use this little guy from harbor freight. Makes a nice 90 deg cut.

Me too, except mine is orange.

sbwertz · Jun 28, 2011

refueler1 said:
staushg69 said:

I use this little guy from harbor freight. Makes a nice 90 deg cut.

Click to expand...

Does that thing actually work. I have looked at it a few times. Does it leave a clean edge?

Yes, it really works! It has a little vise built in to hold the tube, and it cuts pretty clean. Replacement blades are available at HF. It leaves a little bit of burr, but I just rub it on a piece of 220 sandpaper laying flat on the workbench to clean up the edge.

nava1uni · Jun 28, 2011

navycop said:
nava1uni said:

You can use a small hacksaw. If you cut it with support then the tube won't be marred and you can clean the inside with a tat tail file.

Click to expand...

rat tail file?

yes, it rat. You say potato, I say potatoe, etc, etc.
fingers flying across a keyboard make strange words.

U-Turn · Jun 28, 2011

I use my scroll saw to cut the tubes.

randyrls · Jun 28, 2011

I cut the brass tubes with a table saw, in the same jig I use to cut blanks. You do need some way to clean up any burrs that are left from the cutting process.

It consists of a blank drilled with a snug hole and a length-wise cut into the center hole, but not all the way thru the blank.

scotirish · Jun 29, 2011

I also have the Harbor Freight cut-off saw. I added the base and then the slide (to the right in the picture) to allow tubes to be cut to the same length. Note the 1/4" dowels on top, they are set for the ones I cut most often and allow me to set the slide the same every time.
Ron

le_skieur · Jun 29, 2011

scotirish said:
I also have the Harbor Freight cut-off saw. I added the base and then the slide (to the right in the picture) to allow tubes to be cut to the same length. Note the 1/4" dowels on top, they are set for the ones I cut most often and allow me to set the slide the same every time.
Ron

I like your set up Ron. I have the same kit except I did not make that homemade hold down that you made!

scotirish · Jun 30, 2011

Thanks. It was fun to make and it saves time when cutting several tubes the same length. :biggrin::biggrin:
Ron

sbwertz · Jun 30, 2011

scotirish said:
I also have the Harbor Freight cut-off saw. I added the base and then the slide (to the right in the picture) to allow tubes to be cut to the same length. Note the 1/4" dowels on top, they are set for the ones I cut most often and allow me to set the slide the same every time.
Ron

Great idea. I usually just use a clamp to hold a stop block but this is much more elegant.

Showed this to my husband and he just went out and made me one!

Dave Turner · Jun 30, 2011

Being a gadget guy, this little saw looks very enticing. Question: I assume people buy their brass tubing in long lengths. Where do you purchase your tubing? Also, I know there are slight variations in tube inside/outside diameter. Is this ever a problem when friction fitting the pen components?

sbwertz · Jun 30, 2011

Dave Turner said:
Being a gadget guy, this little saw looks very enticing. Question: I assume people buy their brass tubing in long lengths. Where do you purchase your tubing? Also, I know there are slight variations in tube inside/outside diameter. Is this ever a problem when friction fitting the pen components?

I buy mine in 10 packs of ten inch tubes from Woodworker's Source. I've seen them elsewhere as well. Have never had a fit problem.

Custom Tube lengths

BlackPearl

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nava1uni

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