Pipe Cutting

Documentation

This is documentation of the procedure Hacksburg uses for cutting down the pipes for the lightsaber club. This does not cover all of the required safety training or how to use the bandsaw, only the specifics for this process.

1. Starting with the raw stock, mark as many club member tubes as possible per raw stock piece. Be careful to combine shorter and longer final lengths so that the raw stock is used effectively. Mark the length ⅛” longer than the desired length, because the bandsaw does not always cut straight. Mark each tube with some identifier for the person who will receive it. The raw stock is oily, which can ruin sharpies, so make sure to use a paint pen or clean off the metal before marking.

2. Place each piece within the bandsaw vise, align it with the blade, and make a cut. This is typically done as a two-person operation, with one person holding and moving the stock and one person running the saw.

3. Finish the ends. The outside and inside edges of the both ends of the tube need to be cleaned up to remove burrs. The inside edges of the tube can be cleaned up with a deburring tool. The outside edges of the tube can be cleaned up with a file. Optionally, a Hacksburg member can mount each piece in the lathe, face off a small portion of the end of the tube, and file over the end. This leaves a straight, clean end and is the preferred cleanup operation if available.