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06-10-2017, 07:52 AM
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Join Date: May 2013
Location: Mount Vernon, Wa
Posts: 643
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Cutting thin wall aluminum tubing
Fabing up aileron control tubes on next day off. Wanted to insure I get good clean and square cuts. Has anyone used a TCG non-ferrous blade on a mitre/chop saw for this? Or, should I go buy something special?
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Ken W.
Mount Vernon, WA
2020 VAF Supporter
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06-10-2017, 07:55 AM
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Join Date: Aug 2005
Location: Atlanta, GA
Posts: 4,219
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Bandsaw or hacksaw works. Fine toothed is preferred.
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Kyle Boatright
Marietta, GA
2001 RV-6 N46KB
2019(?) RV-10
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06-10-2017, 09:15 AM
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Join Date: May 2013
Location: Mount Vernon, Wa
Posts: 643
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Yep. Looking to make a dead straight cut with minimum hassle. My band saw sucks and a hack-saw would wander without a tube jig. But, my chop saw is sitting there in my garage, ready to go. Just don't want to f- up and have to buy another length of tube stock.
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Ken W.
Mount Vernon, WA
2020 VAF Supporter
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06-10-2017, 09:38 AM
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Join Date: Jan 2005
Location: Ontario, Canada
Posts: 1,544
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A tubing cutter works well. You have to be careful to not take too big a bite each time. Many turns around is better then a few. Take a large half round file and clean out the slight burr and you are ready to go with a perfect perpendicular cut.
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Tom Martin RV1 pilot 4.6hours!
CPL & IFR rated
EVO F1 Rocket 1000 hours,
2010 SARL Rocket 100 race, average speed of 238.6 knots/274.6mph
RV4, RV7, RV10, two HRIIs and five F1 Rockets
RV14 Tail dragger
Fairlea Field
St.Thomas, Ontario Canada, CYQS
fairleafield@gmail.com
Last edited by Tom Martin : 06-10-2017 at 04:06 PM.
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06-10-2017, 10:31 AM
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Join Date: Jun 2005
Location: Raleigh, North Carolina
Posts: 1,128
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Exactly what Tom Martin suggested. Take it slow with progressively tightening the cutting wheel till it pops then dress with a file. Takes a little ( very little) longer time than a hacksaw but you you end up with a nice clean square cut. 
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Tom Norwood
Classic "Short Tail 6A N822PM
TMX-O360. Phase 1
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06-10-2017, 11:03 AM
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Join Date: Oct 2014
Location: Sarasota Fl
Posts: 168
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A Diablo or tenryu non ferrous blade will work beautifully, use a 100 tooth or possibly more if its a 12" blade, hold tube so it dont spin, no problem. It will also cut thick stock, hold material firmly and let blade stop before bringing up until you get experienced, most the problems are from bringing the blade up and small pieces, some line like we 40 will make the blade last a lot longer, I work with aluminum extrusion everyday and the best saw we could is the real sliding 12" mitre saw, very versatile and precise. Beware of the saws that have the blade farther away from the fence to cut taller material, these like to grab the metal and pull it up.
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06-10-2017, 12:25 PM
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Join Date: Aug 2005
Location: Atlanta, GA
Posts: 4,219
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Quote:
Originally Posted by N804RV
Yep. Looking to make a dead straight cut with minimum hassle. My band saw sucks and a hack-saw would wander without a tube jig. But, my chop saw is sitting there in my garage, ready to go. Just don't want to f- up and have to buy another length of tube stock.
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Cut it a gazillionth long, then sand or file it back to a reference line on the tube.
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Kyle Boatright
Marietta, GA
2001 RV-6 N46KB
2019(?) RV-10
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06-10-2017, 02:48 PM
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Join Date: Jan 2005
Location: NC25
Posts: 3,508
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Quote:
Originally Posted by Tom Martin
A tubing cutter works well. You have to be careful to not take too big a bit each time. Many turns around is better then a few. Take a large half round file and clean out the slight burr and you are ready to go with a perfect perpendicular cut.
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Quote:
Originally Posted by NYTOM
Exactly what Tom Martin suggested. Take it slow with progressively tightening the cutting wheel till it pops then dress with a file. Takes a little ( very little) longer time than a hacksaw but you you end up with a nice clean square cut. 
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I am the third with the same recommendation. I did the RV-8 just as described.
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Gary A. Sobek
NC25 RV-6 Flying
3,400+ hours
Where is N157GS
Building RV-8 S/N: 80012
To most people, the sky is the limit.
To those who love aviation, the sky is home.
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06-10-2017, 04:07 PM
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Join Date: May 2006
Location: Pocahontas MS
Posts: 3,884
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+4
Only downside to a tubing cutter is the 'shrunk' ID, which can be removed.
Never tried cutting thin tubing with a table saw, but a regular wood cutting carbide blade works fine on extrusions. Just wear gloves & eye (face) protection.
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06-10-2017, 04:34 PM
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Join Date: Feb 2015
Location: Locust Grove, GA
Posts: 621
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Beautiful cuts
Quote:
Originally Posted by N804RV
Fabing up aileron control tubes on next day off. Wanted to insure I get good clean and square cuts. Has anyone used a TCG non-ferrous blade on a mitre/chop saw for this? Or, should I go buy something special?
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I had an extra Dewalt mitre saw and I bought a Forrest non-ferrous metal carbide tipped blade. Not a cheap blade, but it makes incredibly smooth cuts. I use V blocks when cutting round stock.
I'm a tool hound and I appreciate the accuracy of the chop saw. Like others said, wear really good safety googles as these blades create a lot of flying aluminum chips.
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Krea Ellis
Locust Grove, GA
DA20-A1 "Princess Amelia" - gone home to Amelia Island
RV-7A Phase 2
RV-10 under construction at Synergy Air South
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