I have a length of 2" carbon fibre tube which I need to cut into six lengths. I have very little spare for wasteage and therefore need to get the cuts absolutely square, first time. I have a mitre saw for cutting wood but I fear the blade wouldn't be suitable for cutting CF and AFAIK there is no substitute saw blade available for the mitre saw.

If I use a hacksaw to cut the CF, how can I ensure I get the cut square? I've thought about using a length of aluminium tube as a guide but I'd need to find a tube with a slightly larger ID of the CF tube and I just don't have the time to source it......

Any suggestions?

Phil

Hi there Hellfire,

When I used to work for Wally yachts in Italy, we always used to cut carbon tubes and components a bit oversize, and then very carefully grind back with a die grinder.

If you don’t have much spare, i would suggest you careful mount the tube in a vice, but a band of masking tape around the tube and mark exactly where you want to chop it, you can the cut it with a hack saw. Just take your time and don’t rush it. If you make it 1 mm oversize, you can then machine it back perfect. That’s the way i would (have) done it.

Rob

Might not be cost effective but electrical wholesalers sell a thing for doing armoured glands like a copper pipe cutter but has a hacksaw blade rather than the roller

Phill is it 'Proper CF' or 'CF in clear fiber glass resin' ?

regards

Agriv8

http://www.test-meter.co.uk/products/electricians-tools/kewtechnik-swa-wire-stripper-blade-runner/

Like this mate

jubilee hose clamp as a guide for hacksaw
and maybe not cut all the way through, just cut deep enough to get through the top of the tube, rotate a bit, cut again, etc till you get all the way round

second the jubilee clip method, used this for indicator extensions and required very little filing/sanding to get an nice true end

Half way down right hand column.

http://www.shedworks.eu/hints.html

I wrap a piece of plain A4 printing paper round tubes to get them square. If you line the edges up, you know that you'll get a dead straight cut line that you can mark onto the tube and then cut away as usual with a hacksaw.

quote:

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Originally posted by Agriv8
Phill is it 'Proper CF' or 'CF in clear fiber glass resin' ?

regards

Agriv8

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Just make sure you follow Syd Bridge's advice regarding dust here
http://www.locostbuilders.co.uk/viewthread.php?tid=90496

A properly made carbon fibre layup uses epoxy or phenolic resin, NOT polyester or vinylester. The 'esters' are cheap, but are brittle, and should only be used for cosmetic pieces.

The epoxies and phenolics are tough and resilient, and let the carbon do its job properly.

I'll add to the post that carbon mods made re Syd's post in that reference above.

The comments by Carbon mods are highly irresponsible, and show little regard for or understanding of the the nature of carbon, and epoxies. Carbon is carcinogenic. No ifs buts or maybes. It produces a problem in the lungs worse than asbestosis. This is proven fact.

The hardeners in epoxies are some of the most carcinogenic substances known to man. When making dust, the unused hardeners in the cured layup are nasty to anything they contact. I have SP systems/Gurit locally, and the list of people who leave that place with skin and lung problems is endless.

Do what you wish, don't say you weren't warned/advised. The problems from these don't show up for many years, just like asbestosis. I wonder how the carbon mods guys will be when they are twenty or thirty years older, if they are still breathing at that point?

As pointed out, cut with something with teeth, even very fine teeth, but teeth. If final sanding, have a vacuum extractor removing the dust directly from the workpoint.

I can't stress those points above enough. I've worked with grp for 50 or so years, and carbon for 40 of those years. There are few health and safety warnings about poly and glass. Carbon and epoxies have volumes of health and safety advisories.

Your choices.

Cheers,
Nev.

Just an update on this. I tried the mitre saw before resorting to the other methods and the mitre saw cut the CF tube surprisingly well with little need for sanding.

Phil