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Cutting Aluminum Tubing

2:56
22:11
32.7K views

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What happens here

The creator demonstrates his preferred method for cutting aluminum tubing. He uses a miter saw equipped with a standard DeWalt wood blade. He emphasizes that aluminum, being a non-ferrous metal, cuts cleanly with a wood blade, producing large, easily cleaned chips rather than fine dust or sparks typically associated with cutting steel. He advises allowing the blade to come to a complete stop before lifting it to prevent the cut piece from becoming a projectile. A key 'pro tip' is to cut bends slightly off-center (not perfectly in the middle of the radius). This yields two distinct pieces: one with a shallower bend and one with a more extreme bend, offering greater versatility during the mock-up phase without needing to cut multiple full bends.

Goal: Efficiently and safely cut aluminum tubing sections for custom bends.

Tools and materials

  • Aluminum Tubing Woolf Aircraft — The material being cut for the downpipe
  • Miter Saw Porter-Cable — Cutting the aluminum tubing
  • Safety Glasses TacticalRx.com — Protecting eyes from flying debris during cutting
  • Wood Blade DeWalt — Specifically for cutting non-ferrous aluminum

What they say

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i'm going to cut this one just slightly past the radius of being midway i'll tell you why if i cut it right down the middle then i have two of the same thing it doesn't do me much good if i do it a little bit this way then i got one that's kind of shallow and one that's more extreme and then when i go to mock it up kind of feel out what i'm trying to do then i have different stuff to try and i only cut one piece of pipe pro tip look how prime that is dang it this is just a regular old wood blade regular wood blade if if you haven't figured that out already that's a huge huge thing and something that i learned from jeff jr when he showed me that i was like oh my god this is crazy regular wood blade just does freaking work on aluminum just works so well and that's because aluminum is not ferrous i don't know exactly what ferris means other than that uh it doesn't make sparks whenever you do stuff to it so it has to throw the chips otherwise it just dulls the blade so you need big uh scooping blades to throw the excess and like scoop it away uh whereas steel you want the finer plates to get the tiny pieces this works

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