Removing stock from inside of Al tubing
My passion (after the family and about the same as teaching science) is white water boating, specifically rowing on white water rivers. Last season I picked up a baby cataraft (http://www.aire.com/AIRE/bobcat.shtml) and love it, with the only problem of my legs being a touch too long. As a result I am constantly nailing my kneecaps with my oars, and that is getting old quick.
The frame has crosspieces that secure with spring clips to 1 inch square aluminum stubs that come off of the main frame. the crosspieces sleeve over the stubs.
So I found 11/4″ square, 1/8″ wall aluminum tube at www.Metalsdepot.com to make a new foot bar. Turns out that the inside dimensions of the tube is slightly under and inch, and as a result, did not slide on to the stubs on the frame.
So I grab a bastard file (there is a reason its called a bastard file) and two episodes of Law and Order later I have removed enough stock to get it to slide on.
I want to make a few more pieces, but the novelty of filing out the middle of the tube is rapidly going away.
does anyone have any thoughts on a better way to remove interior volume?
I dont want to sand down the stubs…
Replies
Small sanding drum on a Rotozip
Abrasive burr on a die grinder
Sandpaper spray adhesive to a dowle chucked into a drill
Heating the Al with torch and opening up ends with solid piece of rod
Not sure what woould be easiest or quickest or best.
-srj
He is talking about square tubing. They make a small belt sander that is about a 1" tongue like thing but for just a few it would not be worth it. A Rotozip or Dremel with small diameter rotary file and finish with the bast'd file would be quicker. I do not recall how deep he was having to relieve.
oops, new I forgot something, I want to open up about 3 inches... I may see if I can get a more agressive file... the good news is that aluminum is really soft (as a metal)
I like the shrink fit idea, you heat up the receiver and cool down the stub, bang them together and when the temp equlizes the two have a nice TIGHT fit, this will only work if the differance between the two is a thou or two.
james
I need the larger tube to slide onto and off of the smaller tube as easily as possible, so I can disassemble the frame quickly.