Truss tube cutting tool

[Akshay Subramaniam]

Hi all,

Does anyone have a tool to cut 1” aluminum truss tubes they’re willing to lend me for a couple of hours? I’ve designed and printed all the truss clamps and only need to cut the truss tubes down before I can assemble the truss-less scope that Paul Alsing handed down to me.

Thanks,

Akshay

[Paul Alsing]

Aluminum tubes can be easily cut by any chop saw with a wood-cutting blade, no problem. No need for a special tool. I owned and ran a cabinet shop for over 40 years and cut a lot of aluminum stock over the years!

\Paul Alsing

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From: sf-ba...@googlegroups.com <sf-ba...@googlegroups.com> on behalf of Akshay Subramaniam <aksha...@gmail.com>
Sent: Monday, November 10, 2025 8:43 PM
To: The Astronomy Connection (TAC) <sf-ba...@googlegroups.com>
Subject: [TAC] Truss tube cutting tool

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[Richard Ozer]

I have a pole cutter, but I'm up in Oakland.

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[Akshay Subramaniam]

Paul, I was advised to not use a regular chop saw to cut aluminum tubing because of kickback and projectiles. Is there a method that allows for safe use of a chop saw? Maybe clamping both sides of the tubing?

Richard, thanks for the offer. I'll ping you if the chop saw method doesn't pan out.

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[John Pierce]

This cheap cutter will cut aluminum and copper tubing up to 1-1/8" easily....

https://www.harborfreight.com/tubing-cutter-40913.html

I used one like it to shorten the truss tubes of an Obsession 20" as the focal point was a little too deep in the focuser unless I jacked the primary way up on the collimation knobs.  I also use it on copper water pipe :)

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[Akshay Subramaniam]

Oh wow, thanks for the tip! This is much more affordable than I was imagining. I’ll pick one up at harbor freight tomorrow :)

Akshay

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[John Pierce]

On Mon, Nov 10, 2025, 11:09 PM Akshay Subramaniam <aksha...@gmail.com> wrote:

Oh wow, thanks for the tip! This is much more affordable than I was imagining. I’ll pick one up at harbor freight tomorrow :)

They are also very handy for shortening overly wide bicycle handlebars 😜

[Ted Hauter]

All the bike sizes come with the same handlebars!

I'd go maximum blade tooth count on a chop saw. I went lower one time and the part banged my thumb as a reminder next time.

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[John Pierce]

On Wed, Nov 12, 2025 at 7:11 AM Ted Hauter <thgo...@gmail.com> wrote:

All the bike sizes come with the same handlebars!

I'd go maximum blade tooth count on a chop saw. I went lower one time and the part banged my thumb as a reminder next time.

seriously, these tubing cutters make very clean cuts with no burrs and no risk.