Narrow Brass Tubing - Smothing Out Cut Ends


I'm working with 3/32" (outside diameter) brass tubing that I cut into short lengths (1" - 3") to use with fishing lures. I need a way to smooth out the ends so that the sharp edges will not cut through fishing line that will pass though the tubes.

I've looked for a flaring tool, but cannot find one that will work with thsi diameter of tubing, and I'm not sure that flaring the ends would really solve my problem anyway. Also thought about dipping the ends in apoxy. Any ideas on an effcient way to smooth the ends of the cut tubing?


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  1. Cut the tubing with a jeweler's saw. Use about a #2 or finer blade for that diameter. That alone will create a nice flat edge. Alternatively, use a Dremel or Flex shaft machine with a cut-off wheel -- not as good, but a Jeweler's saw takes lots of practice until you stop breaking blades.
  2. File the end flat to rid the burrs. If you hold the tube in a pin vice you can put a nice chamfer in a second. Alternatively, a touch with a rubber abrasive wheel on a flex shaft machine or dremel will do nicely.
  3. Use a jeweler's conical or bud burr, about 2.5 mm in diameter. Dremel also sells these (overpriced, but okay for one time buy). DO NOT use it in a machine. Put the burr in a pin vice and make a pass or two for the inside chamfer. You might also use a #2 center drill -- that you can hold in fingers because the shank is bigger -- a twist or two and you've got a nice chamfer on the inside.

The entire process I described takes less time than it takes you to read the above. I'd make them up in a mini production line -- one operation at a time and do a few dozen at a time.


Reply to
Boris Beizer

I do this with a very small carbide countersink, and simply put a chamfer inside the ends. Typically I dress the outer edges with a fine jewlers file.


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Reply to
jim rozen

chuck the tube up in your drill press, crank the rpms up, roll up a small piece of fine emory cloth & insert it into the end of the tube

Reply to

Do you have a lathe? If not, you now have an excuse to get one. If (when) you do, cut the tubing in the lathe with a really sharp parting tool and then touch up the inside with a sharp countersink to remove what little burr will be there.

If you want to flare the end a little, you could do it with the work spinning and a tool that looks like a rivet set for hollow end rivets in the tailstock.


Reply to
Ted Edwards

I was wondering how long it would take for someone to suggest this, the best possible solution to this simple problem! I agree! I've deburred such items that way as long as I can remember.


Reply to
Harold & Susan Vordos

Cut it with a dremmil tool and you will have very little to polish. Use the thin cut off tools.

Reply to
Leonard & Peggy Brown

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