How to Cut Aluminum Pipe

The aluminum pipe has a wide range of applications. Aluminum pipes are commonly used as conduits for running electrical wiring, in chain link fencing, and are used structurally in carports and detached garages.

Due to the gauges or thickness of aluminum used in these scenarios, there is not a single best way to cut aluminum. Below I will explore several scenarios and methods for cutting aluminum pipe.

How to Cut Aluminum Pipe for Electrical Conduits

Running outdoor electrical wiring requires using conduits in most locales. Conduit protects your wiring from the weather, nibbling critters, and you. No one wants an accidental jolt of electricity in a brief moment of attention.

Unless you are working with a gargantuan industrial conduit, the simplest way to cut conduit is by using a pipe and tubing cutter. The name of the tool is pretty much on the nose for this application.

Pipe and tubing cutters (also referred to simply as pipe cutters or tubing cutters) are simple C-shaped clamps. At either open end of the C is a small, hardy cutting wheel. There are limitations to this cutter.

By and large, the largest available pipe and tubing cutters work up to 1 1/8 inch pipe. Pipes larger than 1 1/8 inches will require different methods or specialty pipe and tubing cutters.

Let me walk through using a pipe and tubing cutter. I will include some tips and tricks along the way.

Tools:

• Pipe and tubing cutter appropriate for the diameter of the pipe you plan to cut
• Tape Measure
• Black magic marker
• Electrical tape
• Optional: nitrile work gloves

Method:

1. As with cutting any pipe, start by determining the length of aluminum pipe you need to cut.
2. Using your tape measure, measure the length of the pipe to be cut.
3. Make a small mark with your black magic marker at the point where the pipe needs to be cut.
4. A tip I recommend for cutting metal pipes is to use electrical tape to wrap around the pipe as a guide. Align an edge of the tape with the mark from your black magic marker. Wrap straight around the pipe. If done correctly, both edges of the tape will perfectly align when you have gone all the way around the pipe.
5. Optional: put on nitrile work gloves. These gloves will help you securely hold the pipe while spinning the pipe and tubing cutter.
6. Expand your pipe and tubing cutter completely.
7. Place the pipe and tubing cutter over the pipe. The pipe should touch the center of the back wall of the C. 
8. Tighten the clamp until the cutting wheels lightly touch the pipe. Do not overtighten.
9. With the cutting wheels making light contact, spin the pipe and tubing cutter until it spins free around the pipe.
10. Slightly tighten the pipe and tubing cutter.
11. Spin the pipe and tubing cutter again until it spins freely
12. Continue this process of gently tightening and spinning until the pipe is cut. 
13. Most pipe and tubing cutters include a deburring tool. After the pipe is cut, spin the deburring tool around the inside of the cut end of the pipe until it is smooth and clean.

Tips:

• Be sure that the cutting wheels on your pipe and tubing cutter and directly across from one another. If they are even slightly askance, the pipe and tubing cutter will bind up and either not cut the pipe or produce a jagged cut.
• A permanent or heavy clamp such as a vice can be used to hold the pipe steady while you cut if freehanding the conduit is too unwieldy.

How to Cut Aluminum Fence Post Pipes

If you are putting together a DIY dog cage or fencing your yard to keep your dog in, you will have to cut fence posts. The common diameters of aluminum fence posts are either 2 inches or 2 1/2 inches. 

Given the thickness of these aluminum fence post pipes, pipe and tubing cutters are not a good option. I will cover two different methods for cutting aluminum fence post pipes.

How to Use a Hacksaw to Cut Aluminum Fence Post Pipes

Using a hacksaw is the safest and cheapest way to cut aluminum fence post pipes. Aluminum is a relatively soft metal. A hacksaw with a fine metal blade can make short work of a solitary pipe. 

Tools and Materials:

• Stable surface
• Tape measure
• Black magic marker
• Electrical tape
• Clamps to hold aluminum fence post pipe steady
• Hacksaw with fine, metal cutting blade
• Safety equipment: safety glasses, earplugs, and gloves
• Optional: cutting oil, metal file

Method:

1. Determine the length you need to cut.
2. Use a tape measure and marker to mark the appropriate location for your cut.
3. Wrap electrical tape around the pipe in a straight line along your cut line. Both edges of electrical tape should perfectly overlap.
4. Secure your pipe into place using your clamps. Do not overtighten. Aluminum will bend or dent easily under direct, pointed pressure.
5. Put on your safety equipment.
6. Optional: apply cutting oil along your electrical tape.
7. Align your hacksaw with the edge of the electrical tape and gently begin sawing. This is both the most important and difficult step in cutting your aluminum fence post pipe. Allow the saw to do the work but not apply much force while keeping your hacksaw blake next to and parallel to your electrical tape.
8. Continue cutting through the pipe. The offcut or extra portion of pipe can be gently bent away from the cut to allow your hacksaw to move more freely
9. If you have burrs at the end of your aluminum fence post pipe, you can use a metal file to smooth out the end.  

How to Use a Miter Saw to Cut Aluminum Fence Post Pipes

While a hacksaw is great if you have one or two fence posts to cut, a miter saw may be necessary for larger projects. Using a powered miter saw will be noisier, have a larger potential for injury, and be more expensive.

We also recommend this method if you are cutting square aluminum pipes.

Tools:

• Stable cutting surface
• Powered miter saw with the fine-toothed metal cutting blade installed
• Tape measure and black magic marker
• Cutting oil
• Safety equipment: safety glasses or face shield, ear plugs, nitrile-coated work gloves

Method:

1. Measure and mark on the post where you will make your cut.
2. Ensure that your miter saw is unlocked and secure and stable on your work surface. If you are working with long aluminum fence post pipes, you may need to find a way to extend a level surface outward from your miter saw to prevent your pipe from rocking while cutting. The easiest way to do this is with sawhorses. 
3. Put on safety equipment. Along with keeping your hands away from the saw blade, protecting your eyes and ears will be especially important when cutting metal with a miter saw.
4. With your hand off the miter saw trigger and the length of the pipe supported, press the pipe securely against the rear fence of the miter saw.
5. Slide the pipe along the fence until your cutting mark is aligned with your blade. With your hand off the trigger, lower the blade to the pipe to ensure it is in the proper cutting location.
6. Apply cutting oil to the pipe at the cut site.
7. With the blade away from the pipe and with the pipe held securely in place, squeeze the miter saw trigger and power the blade up to its full RPMs.
8. Lower the blade into the secured pipe. Apply gentle pressure until the blade was cut cleanly through the aluminum fence post pipe.
9. Release the trigger and allow the blade to come to a stop before raising the blade away from the cutting surface.
10. Debur the pipe end with a metal file if necessary.

Basic miter saws aren’t that expensive and have a wide range of uses on other projects.

Conclusion

Cutting aluminum pipes is a careful balance between gentleness and sharp blades. The softness of the metal makes it possible for most DIYers to cut it at home with readily available tools. When cutting metal, always prioritize your immediate and long-term safety by using personal protection equipment.