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[Martin (Admin)]

I need to make a hand rail from brass tube as below...... any ideas in a quick and simple idea please?
2 lengths of Tube  about 3mm by 500mm

[Circlip]

      If you have a Dremel with a thin fine blade you can clamp it like a 'Table Saw with a jig to locate and slide the
       tube through the blade arc, to just pierce the tube. Hope no Elfin's reading.

[John W E]

Hi ya Martin

As Circlip suggests, if you have a Dremel with a slotting disc, what you can do is first of all file a flat along length of the tube.  Clamp the tube in a vice, and carefully slice it with the cutting disc along the flat.  The flat helps to prevent the disc from skidding off, down the side of the tube.  The other thing is, if this doesnt work, invest in a milling machine, they are cheap   

aye
john e
bluebird

[DickyD]

Hi ya Martin

As Circlip suggests, if you have a Dremel with a slotting disc, what you can do is first of all file a flat along length of the tube.  Clamp the tube in a vice, and carefully slice it with the cutting disc along the flat.  The flat helps to prevent the disc from skidding off, down the side of the tube.  The other thing is, if this doesnt work, invest in a milling machine, they are cheap   

aye
john e
bluebird

It's going to have to be a mighty fine disc and a steady hand to cut a slot in a 3mm tube 

[meridian]

If I was you Martin, I'd find someone with a small milling machine to cut the slots for me. I think that this is the only practical solution, particularly over a length of 500mm. Even then it's going to be a bit tricky.

[Colin Bishop]

You must have very small bannisters in your house Martin.  :)

[Circlip]

    If you're going to mill it  someones' going to have to find milling cutters thinner than the Dremels. Poops bros. don't
    know what they are called now have fine slitting blades. Failing that co you know anyone with access to a LASER or
    a WATER JET CUTTER.

[DickyD]

Does it have to be cut or can you do what you want to do differently Martin ? :-\

[meridian]

Chronos Engineering Supplies sell a 1mm diameter milling cutter but even that's a third of the diameter of the tube in question. I don't know what the wall thickness is but you certainly wouldn't have much left! Has this been done before Martin?

Cheers, Andrew

[hobbyman]

Hi Martin
out of interest ,why do you need a slot in the tube ??

[pops]

For a slot with rounded ends, I use my milling machine. One could also drill a hole at each end of the slot and use an abrasive cut off wheel, in a
Dremel tool, to make the two cuts between the drilled holes. Square ends on the slots would require some filing to square the round holes.

[DickyD]

For a slot with rounded ends, I use my milling machine. One could also drill a hole at each end of the slot and use an abrasive cut off wheel, in a
Dremel tool, to make the two cuts between the drilled holes. Square ends on the slots would require some filing to square the round holes.

The tubes only 3mm diameter pops.

[pops]

Okay.........A very small milling machine or a very thin cutoff wheel.  :)


I promise to learn to read one day DickyD :)

This may be a job for a jeweler. 



Update:

My smallest milling bit is .04 in that equates to 1.01mm

[HS93 (RIP)]

slide a tight fitting rod in the centre so you can grip the tube in soft jaws, and then set up a GOOD steel ruler and a sharp knife score it through start with light cuts it will not be quick ,you may want to anneal it first to soften but the likes of k&S at that size is normally soft and thin walled and will score through quite quick . I cut the inside of some of my doorways using this method and in small tube there is minimal loss material. if it can be cut in to shorter lengths that would help

Peter

[Martin (Admin)]

I'm helping someone with a Graupner Pegasus and the aft gunwhales are very flimsy thus wavy.
The slotted tubes are to straighten and 'beef' the sides up.

[Colin Bishop]

Could you get away with using square channel brass? (or even plastic) I have used this to beef up the bulwark edges on my Dean's Medea. If you use brass you could use an abrasive cylinder in a mini drill to round off the edges to give a rail effect. Might not be 100% accurate but it would be neat and quite effective,

[meridian]

What about half round styrene strip stuck on each side? Would that solve the problem?

[GaryM]

If you know anyone with a pantograph, they could cut it - I used to be a die sinker and regularly used cutters of around .0031"
I could find out a few addresses if you want?

regards
Gary :)

[tonyH]

Why not use 2.5mm mains cable. Cut along the insulation only (red or black to suit your mood!), leaving the wire in and just superglue on as required.

Tony