On Thu, 09 Sep 2004 09:34:55 GMT, david
wrote:

hi,

I am using 3/4" OD aluminum tubing as balusters for deck rails. I need
to cut almost 400 of them to length. I was hoping for suggestions on
the most efficient and painless way to do this. I have woodworking
tools such as band saw, table saw, miter saws, jig saw, etc...

any advice appreciated...

thanks,

david
greenville, sc
Several years ago I was cutting 1/2"copper tube using the regular
wheel type cutter but made up an expanding rubber plug to fit the i.d.
of the tube. This was just a piece of tubing between washers on a bolt
with a nut. I then gripped the threaded end of the bolt in my 3/8 VSR
drill. Running the drill forward, there was enough interaction between
the copper tube, rubber, washer and nut to expand the plug and spin
the tube in the cutter, reamer, and emery paper. Then, a quick reverse
and the piece was released ready to insert and spin the next piece. It
sure speeds up the use of a tubing cutter if the tubing is turning at
a few hundred RPM, and a tubing cutter gives a nice square cut.
With long stock, this would be a two person job, but shouldn't take
long to cut 400 pieces. I would go with a blind hole in a block of
hardwood as a bearing for the free end then measure back from the
bottom of the hole and make a reference mark to locate the cut.
Gerry :-)}
London, Canada