Total posts : 45366
I got that part done and it works great. Here’s how I did it:
I have a little Delta bandsaw and found a metal cutting blade for it. I used the guiide fence and sawed away. The overlap was fine and the clamps securely hold the assembly together.
Other ways to do it would be to lightly clamp the pipe in a vise and use a dremel cutting wheel. This is tricky and dangerous as the dremel wheels are very prone to breaking. If you try it, make sure you protect your eyes.
In the old days, when all I had was a hacksaw and a vise, I would wrap the pipe with several layers of masking tape. Use a fine toothed blade and go slowly. The tape keeps the blade from slipping.
Cutting straight cuts is always a problem with hand tools. It will help if you use the tape method if you just do one cut at a time and keep the blade angle very small, almost parallel to the pipe. With the tape you can probably get a pretty straight cut.
When you clamp the pipe in a vise, don’t clamp where you are cutting. Leave the 4 inches or so sticking out of the vise. Otherwise, the vise will squeeze the blade and you will get nowhere.
Hope this helps. Let me know.