Cutting Metal Tubing

Steel tubing can be cut with several different tools depending on the size of the material, required accuracy, and available equipment. Always secure the tubing before cutting and wear appropriate eye protection.

Hacksaw

A hand-powered hacksaw is a versatile tool for cutting thin walled steel tubing. Secure the tubing in a bench vise so it cannot move while cutting. This makes the cut cleaner and more accurate while keeping your hands away from the saw blade.

Begin with light pressure to establish a groove, then use long, steady strokes through the material. Let the saw blade do the cutting rather than forcing it. Use the entire length of the blade.

Many people use a hacksaw incorrectly by quickly moving the saw back and forth in short strokes with only the center of the saw cutting the material. THis quickly dulls that section of the bland and is much harder.

Portable Bandsaw

A portable bandsaw makes quick work of cutting through steel tubing and is useful for both straight cuts and rough fabrication.

Secure the tubing before cutting and keep both hands on the saw. Allow the blade to reach full speed before contacting the metal, then guide the saw steadily through the tubing without forcing it.

Support both sides of the material so the cutoff piece does not fall unexpectedly or pinch the blade.

Deburring Cut Tubing

Cut steel tubing will usually have sharp edges and burrs.

• Remove sharp burrs with a metal file.
• Use sandpaper or an abrasive disc to smooth the cut edge.
• Remove loose metal from both the inside and outside of the tube.
• Check the edge with care before handling or fitting the tubing.

Clean, deburred edges are safer to handle and make it easier to accurately fit pieces together for welding and fabrication.