Shopsmith Forums

If you even purchased the 2' lengths of t-track from Rockler you will know the tubing I'm trying to cut.
I've tried with a thin hand saw and with the miter saw both have been less then wonderful.

In the end I want a couple of "viewtainer" sort of containers that are 10" long. I can do a couple more test cuts before I have to get the money cut.

Ed

I don't have any good advice for you. Last time I tried using the bandsaw and then a table router but got similar results as you. But the router was probably better, just not great.

Would a bandsaw with a fine blade make a nicer cut?

I would insert a wood dowel the diameter of the tube and then cut it. It would need to be a tight fit.

I’m leaning toward the dowel plug idea myself, but with a twist.

First cut the tube(s) to rough length with a saw. Chuck up an oversized dowel (or block) in lathe mode, and turn a slightly-tapered tenon to fit inside the tube. Mount the tube “between centers” and dress the rough cut with a parting tool, right on top of the tenon. The tenon is semi-sacrificial, but it should be good for several cuts.

If you turn a groove in the tenon at the part-off line, you could even sand/polish the cut end of the tube.

Hot knife.

Insert a dowel into the plastic tube so as to maintain its dimension, and then use a nice, sharp tubing cutter to "slice" the plastic instead of trying to cut it.

Just my 2 cents.

Edit: I think your lathe approach would probably work too, but would be more work.

I would try the dowel inside then mounted in chuck and while turning I would use a utility knife to do the cutting. If I would use the bandsaw I would use dowel inside with tape around the plastic to then make the cut, if necessary then sanding disc to smooth edge.

I wonder if a wooden dowel inserted in the plastic as has been suggested along with a pipe cutter would give you a clean cut.

I have been thinking about this since I read the post yesterday. My suggestion would be to use an X-Acto saw blade. They have very fine teeth for doing delicate work.