How to cut small tubes without smashing

Model Railroader General Discussion (Model Railroader)
1

I have some 3/32" aluminum tubes from K&S Precision Metals. I’m trying to cut them to make a set of pipes for a building.

I’ve tried cutting them with a small saw, but didn’t like that. I also tried just cutting them with a side cutter, but just like I feared, it smashed the tube.

Is there an easy way to cut aluminum tubing and get a clean cut?

2

John,

Did you try a razor saw? The fine teeth should slowly cuff through the aluminum material without damaging it. You might also want to consider a miter box. Lastly, how thick are the walls of the 3/32" (0.094") tubing?

Tom

3

Micro Mark sells tube cutters. I wonder if that is the answer?

Rich

4

What if;

You lay the tube on flat surface , Useing a ‘‘new’’ no11 blade, roll the tube back and fort, apply steady but slight pressure on knife.

This works well with wood and plastic, being that alum. is soft it might be worth a try.

5

I don’t have a razor saw, but that may be an investment I need to make.

I will try UncleButch’s suggestion with the blade. I’ll let you know how I do.

Thanks.

6

Never tried the exacto thing, may work on very thin wall.

I’ve had good luck placing a solid rod (brass) inside that’s a good fit to the I.D., then razor saw, very fine tooth.

7

If you have a Dremel and a small cutting wheel bit might work.

TF

8

Well!

I just tried rolling the tube with the exacto blade, and guess what? It cut smoothly through in about three rolls, and it did not distort or crush the tube!

Thanks, UncleButch. I would have never thought of that.

9

Put something in the tube - a piece of wood close to the inside diameter would keep the tube from crushing and still cut along with the tube, or even a scrap sprue. Or something harder, like a drill bit, the shank end, but then you have to be careful since it will dull the knife blade.

–Randy

10

The K&S tubing cutter should do the trick, #296 cutter = 1/16" - “5/8” OD

Peter

11

Go to you Local Hardware Store and get a small pipe cutter from the plumbing department.

12

You can get a simple tubing cutter at any hardware store, home improvement centre, etc. I use mine for brass and plastic tubing, and also for copper pipe.

An X-Acto knife is useful for cutting brass, aluminum and styrene tubing, using the roll back-and-forth method, but also works well for cutting brass and phosphor-bronze wire, up to at least .040" diameter, and will also cut stainless steel wire up to about .020", and piano wire under .010".
I use old #11 blades that have worked their way down the useability-scale, from cutting out decals, trimming small parts, cutting wood or styrene, and cutting sheet brass and aluminum.
While I normally do my modelling work on a sheet of glass, it helps the cutting-while-rolling method if you put down an appropriate length of masking tape on which to roll the material, as it prevents it from skidding under the blade.

Wayne

13

A pipe cutter.

I didn’t know you could cut such small tubing with these things Wayne. I guess I’ll have to try it sometime[;)]

TF

14

50+ years ago in the kinks column of MR someone said to fill tubing with sand to bend it. Would work for cutting also.

15

I agree with Peter. As far as I am concerned and with My own experience on the subject and redoing many brake lines, fuel lines for trucks & cars, it really is the only way to go.

https://www.walmart.com/ip/K-S-Engineering-Tubing-Cutter/37290922?wmlspartner=wmtlabs&adid=22222222222025107097&wmlspartner=wmtlabs&wl0=e&wl1=o&wl2=c&wl3=10375588027&wl4=pla-1105725791598&wl12=37290922_10000001195&wl14=K%20S%20Tubing%20cutter&veh=sem&msclkid=0494b4c29fcf1e0a8c1aea52e77e30f5

Brass & Copper tubes for axles on 1/87 scale for Sylvan trucks kits:

Photos may be clicked on for a larger view:

Take care! [:D]

Frank

16

I bought one of these years ago. It was labelled “Small Tubing Cutter”. I think the “Small” refered to the size of the cutter, not the size of the tubing to be cut. I have used it more to cut copper water pipe in tight places than for model work.

I have a small powered chop saw with an abrasive disc to cut small tubing and other metal shapes. It has a saw blade for wood or plastic cutting.

Another way is to file a notch in the tubing, break it off and file to the final dimension.

Mark Vinski

17

Thanks for all the ideas, everyone!

18

The small tubing cutter shown above is both smaller and for smaller tubing than larger ones. I have three different size tubing/pipe cutters for various jobs. The bigger ones do not cut small tubing very well, if at all.

Good luck,

Richard

19

John, I cut my tubing exactly like Uncle Butch suggested. I am glad it worked for you also.

The only hard part is making sure the blade is 90 degrees to the tube when you start.

-Kevin