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Old 06-17-2014   #1
Denver, Colorado
Paddling Since: 70s
Join Date: Jul 2008
Posts: 63
Cutting Aluminum Pipe?

I am doing some 1 1/4" (NRS size) Aluminum pipe/frame modification....I need to do about a half dozen cuts....yesterday it took me about an hour to do a hacksaw cut.....Home Depot price for a 12" metal cutting miter saw blade (for my neigbors saw) is $60! ....any suggestions for cheaper way to cut that won't take me all week to do? thanks, Chet

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Old 06-17-2014   #2
Thronton, Colorado
Paddling Since: 2008
Join Date: Mar 2009
Posts: 665
Try a metal cut-off disc instead. A lot cheaper. I used one with a circular saw last year when I built my Mini-Max frame. It worked fine for what I needed.

Maybe something like this for the mitre saw?

Diablo 10 in.x 3/32 in. x 5/8 in. Metal Cut-Off Disc-DBD100093L01F at The Home Depot

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Old 06-17-2014   #3
Salt Lake City, Utah
Paddling Since: 1969
Join Date: Apr 2009
Posts: 187
Skil/circular saw with 40 tooth carbide blade works fine as well, just make sure you clamp pipe securely. Cut slowly until you get the hand of it - if you cut too fast the teeth will clog w/slag.
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Old 06-17-2014   #4
jakebrown98's Avatar
Portland, Oregon
Paddling Since: 2001
Join Date: Mar 2008
Posts: 165
Do a bit more research to be sure, but I was planning to try using my chopsaw with a regular carbide tipped blade. I know it sounds weird, but carbide is soooo much harder than aluminum and the blade spins so fast that you can make cuts with it easily if you go slow. At least that is what the interwebs told me--I haven't tried it yet. As I said do a bit more research and video scouting to be sure.
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Old 06-17-2014   #5
Denver, Colorado
Paddling Since: 2000
Join Date: Jan 2014
Posts: 152
Go to Harbor freight, and buy an angle grinder, and get some metal cut off discs. You will spend less $30, and it is very very useful.
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Old 06-17-2014   #6
aka The Curmudgeon
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Hopelessly Stuck in Yesterday, Colorado
Paddling Since: 1994
Join Date: Feb 2008
Posts: 322
I've had good results with my cheapie ($19?) Sawzall (aka Reciprocating saw) from Harbor Freight. Made 6 cutoffs in my 2" tubular frame in less than a minute per. Good idea to make a couple of practice cuts first though. I think the saw even came with a few blades as well.
Don't Wanna Die Askin' for Another Chance
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Old 06-17-2014   #7
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Boulder, Colorado
Paddling Since: 1995
Join Date: Oct 2003
Posts: 2,727
Just stick a cheap wood cutting metal blade in that nice miter saw. Even a seven.25" should do it, just shim the table up. Spend ten bucks on a marathon or diablo.

(Seven two 0) 298-2242

(seven two 0)-298-2242
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Old 06-17-2014   #8
albuquerque, New Mexico
Join Date: Jan 2011
Posts: 134

if you don't want to use power tools or clean up dirty edges, a pipe cutter is faster and easier than a hacksaw, cheap, and super accurate.
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Old 06-17-2014   #9
boulder, Colorado
Paddling Since: 2008
Join Date: May 2013
Posts: 9
Please don't use the cutoff wheels! They are meant for steel. They will cut some, then clog up with aluminum, then they just get hot and are in danger of blowing apart

The coarser tooth saw suggestions are a much better idea
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Old 06-17-2014   #10
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salmon, Idaho
Paddling Since: 2004
Join Date: Mar 2012
Posts: 639
i'm willing to bet if you made your marks and took it into any metal shop they would do the cuts for 10 or 20 bucks if not free...

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