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The Magic Cafe Forum Index » » The workshop » » Cutting a Slot in Aluminum Tubing (0 Likes) Printer Friendly Version

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Craig Dickens
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Chance, I wouldn't recommend it either for the average Joe. I was responding to earlier posts that stated it was easy or made incredibly unsafe recommendations. It wasn't intended for an experienced worker like you. My intent was to explain what was actually involved and what tools and accessories were required to do the cut. You are absolutely correct in suggesting he farm it out.
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Chance Wolf
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Yeah, I got your intent! I was glad you had the patience to write up the entire process Smile
I am always learning and enjoy hearing and learning from other pros.
Much appreciated.
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Mike Maturen
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Chance and Craig:

Thank you for your great words. I would also recommend farming this out. I am not great with power tools anyways, so I would likely end up cutting off some crucial piece of personal "equipment".
Mike Maturen
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David P
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There might be a problem once you have successfully made your slot.I have worked metals all my life and have noticed with some metal tubing and pipe that once you have made your cut, stresses are relieved and the diameter expands/folds outwards. Should this happen, you would have the correct diameter at each end, but larger diameter towards the center of the length of your tube. You could probably correct by tapping with a rubber mallet, while supporting the tubing on a piece of wood. Something to consider. It will depend on your aluminum tubing.
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When cutting aluminum on a table saw we use a “KOOL MIST” spray system to lubricate the blade. The spray nozzle has a convenient magnetic base that we attach under the table saw to continually lubricate and cool the blade. It works great and allows the blade to make extremely smooth cuts.
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Profile of chleby
If you're good with a grinder you could attach a cutting wheel and do it that way. We have used this method on several of our projects.
Lighting Designer- Dan Sperry MAGIC SHOW Times Scare NYC
Lighting Designer- Dan Sperry Spring 2011
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Profile of Paul_Rheaume
Craig Dickens has a working method for the home shop. I have used this many times to cut aluminum blades etc. I cant over encourage the safety portion and can only add one thing. load the blade with parafin wax as a lubricant and to keep the metal from building up on the teeth. check often.
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