Ok, seriously, patience is the key. Extremely sharp Xacto knife or
finetoothed razor saw are the tools. Mark a very accurate guide line and
stay on it. Placing a wooden dowel inside the BT would give a solid surface
to cut against if using the Xacto knife.
TRA # 8975 L2
NAR # 79398
Randy, If you don't have one, you must get a 3 foot long chunk of aluminum
bigger the legs the better, around 4 inches. Clamp a block on the inside of the
that lets the BT hang over on your cut line. Then, very slowly rotate the tube
the angle while you hold that super sharp x-acto against the end of the angle on
If you want to get really precise, make a small (1/2 inch) slot near the end of
This slot is perp to the centerline of the angle. The slot is the knife slot.
rotate your tube nesting in the angle and gently insert the knife in the slot
makes contact with the tube wall. Rotate, push, cut, repeat as necessary.
Make a line around the tube - and use a Razor saw. Do not cut through the
first time around, just slowly work around, scoring the top of the tube.
Then on the 2nd run around you can begin to cut through.
I use something similar in design to cut tubes. I screwed a single edge
razor blade to the edge of my miter-box. The blade protrudes 2 or 3 mm at
most. I clamp a block on the other side of the miter-box at the distance I
need the cut tube to be and slowly rotate the tube against the blade while
lightly forcing it into the miter-box corner and keeping it against the
block. It sounds complicated but really is a simple and easy to use tube
Having said all that, I've also used Stephen Corban's technique
CAR S767 L2
tube nesting in
angle on your cut
end of the angle.
"Randy" wrote in
Get one of those honkin' big hose clamps. Get a piece of BT-100 coupler,
or make your own with a couple of short rings of BT-100 (doesn't have to
be precisely cut). Put the coupler inside for support, gently tighten the
clamp down and carefully measure so that it defines a plane perpendicular
to the axis of the tube. Put a new blade in your knife. Make a few passes
over the tube. Rotate the clamp so the tightener gets out of the way of
the section it was blocking. Stiffen the cut edge with CA and lightly
sand to finish.
Nope. Manual can-opener. The good one with the blade that's gear
driven from the can-rotating thingy...
Number One Son's been selected to go to District Science Fair with his
TEA Laser, so now the "perfect gift" would be a big-ass selenium
rectifier with enough bulk to deal with a direct ~10kv DC short off a
You know what would be *really* hilarious? Somehow finding a
"Victoria's Secret" box that could contain an axe! Bet the wife,
*and* the sister-in-law would ask you plenty of questions about that
I always wrap a strip of cardstock tightly around a tube, securing with tape,
then lightly score the tube with a sharp x-acto blade using the edge of the
cardstock as a guide. Then, continue for 2 or 3 more passes, until the cut
goes through. Very clean and perfectly straight.