Suggestions for cutting accurate square ends on styrene tube

[Brandlin]

HI guys

I'm looking for a very accurate way to cut styrene tube that creates a square end, but also enables repeatable lengths to be cut.
I'm cutting rod from 1.2mm diamter up to 3.2, and hollow tubes from 2.4mm diameter up to 5.5mm.

I'm already using one of these.



While its great for cutting the smaller diameters it 'wanders' while cutting the thicker tubes, which leaves an angled cut.

I've seen this....



but at £40 its expensive to buy without some sort of recommendation. Anyone used one regularly?

Anyone have other suggestions?

[Emberbreeze]

When I cut the one supplied to introduce a kink in the chimney I used a hobby saw. Would a guide (like a mitre block) and hobby saw be more accurate?

[Brandlin]

When I cut the one supplied to introduce a kink in the chimney I used a hobby saw. Would a guide (like a mitre block) and hobby saw be more accurate?

possibly

Its the repeatable lengths thing.  for example for the stables I have to cut 21 identical 12mm lengths of 1.3mm styrene rod for the railings. Thats 252 lengths for a dozen kits (my minimum order volume). The chopper is great at this becasue i set up a little jig i made and clamp it in place, sit in front of the TV and cop away and bag up.

But doing the wider tubes that form the centre of the roofs is causing problems. There are fewer of them but I can't clamp my similar jig for these tightly enough to prevent the blade from wandering as it cuts through the tube - i think the blade and arm deflect a little.

A hobby saw wouldn't suffer from this deflection as it cuts away the material rather than a smooth kknife blade that tries to force its way through. But for the watchtower I need to make 6 accurate cuts per kit in the 5.5mm tube to make the pillars. I'll make up a stop that clamps to my mitre box and give it a go - i dunno why but in my head this seems less repeatable than the chopper... might just be my brain though.

thanks ben

[Klute]

On a larger scale in my patternmaking days, any repeating stuff similar to this was done on a radial arm saw with a clamp on the back rail as a distance stopper.

Problem I see for you is if the blade is sturdy enough not to wander then its more likely to crush the styrene tube. You really need to saw cut them I reckon. Bet you could knock up a small scale radial arm in no time.

[Brandlin]

I have a radial arm saw in the garage - but that's for wood cutting! well, actually its a compound sliding mitre saw..similar but not identical


Yeah - I am beginning to think that sawing in a mitre box is the only way to go. just takes a little longer, but it might be the only way to get the results i want.

[Rick]

I'm just wondering if you could get a small enough diameter pipe cutter - you know the ones plumbers use to cut copper pipes?

[Rick]

Actually, an adjustable pipe cutter might be the answer, most of them I've looked at can adjust to sizes within the ones you mentioned and look to be cheaper than the £40 price tag for your other cutter. Not sure how effective it would be, but it seems a fairly good way to do it.