Quote from: Raimy on September 27, 2017, 01:05:23 PM

Quote from: d57heinz on September 27, 2017, 11:54:18 AM

Quote from: Raimy on September 27, 2017, 11:02:38 AM

So, I decided to try my hand at making one of those open air frames I have seen around. I found a place that sells 1" square aluminium tubing and plastic connectors to make what I want.

My question is how do I cut the dang stuff. I have tried a hack saw, which works but it is hard to get clean square cuts. I have also tried a metal cutting wheel, but it left too many metal burrs to clean up afterwards. I was thinking maybe a band saw with a jig might work well, but I don't have one. Any tips from people who have gone through this, preferably without having to buy expensive shop equipment?

Rent a chop saw. Get a 10 inch - 12 inch with a metal cutting disk. Makes nice square cuts. You may still have a slight burr at the end of the cut but a file will take care of that nicely. Good luck with your project.

BR

Yeah, I tried that already, that is what I meant by the metal cutting wheel earlier. It did make the cuts nice and square but the deburring afterwards was a real pain and took more time than using a hacksaw.

Do you have a dremal tool?
It removes the burrs fast.