How to Cut Black Aluminum Tubing

This guide covers Inline Design Black Matte Aluminum (6005A-T61) round and square handrail tubing with a 0.083 in (2.1 mm) wall. It does not apply to satin stainless steel or black powder-coated stainless steel tubing — for those, see How to Cut Stainless Steel Tubing.

What you need

• A miter saw (chop saw) or other saw that takes a round carbide blade
• A carbide blade made for aluminum / non-ferrous metal, for example:
  • Home Depot: Diablo 10 in. 80-Tooth Non-Ferrous Metal Blade (D1080N)
  • Home Depot: Diablo 12 in. 96-Tooth Aluminum Blade (D1296ND)
  • Harbor Freight: Hercules 10 in. 84T Non-Ferrous Metal Cutting Blade (57941)
• A clamp or vise with soft padding
• Painter's tape and a fine marker
• A deburring tool or fine file
• 90% isopropyl alcohol and lint-free towels
• Black matte spray paint and cotton swabs for touch-up (see below)
• Safety glasses and hearing protection

Use a blade that fits your saw, and make sure the maximum RPM printed on the blade is at least your saw's speed.

Before cutting

• Measure twice. Fittings, joiners and elbows slide inside the tube, so take your cut length from your drawing and check it with a dry fit before the final cut.
• Wrap painter's tape around the tube at the cut line and mark the cut on the tape. The tape also protects the painted finish at the cut.

Safety

• Wear ANSI/ISEA Z87.1 safety glasses with side protection and hearing protection.
• Clamp the tube. Never hold it by hand while cutting.
• Aluminum chips are sharp and hot. Let the blade stop fully before lifting the saw.
• Follow your saw's and blade's instructions.

Cutting steps

1. Support the tube so it is level with the saw table on both sides.
2. Clamp it firmly near the cut line, using padding so the finish is not marked.
3. Start the saw and let it reach full speed before touching the tube.
4. Cut with slow, steady pressure.
5. Let the blade stop before lifting the saw.

Deburr and clean

1. Remove the sharp inside and outside edges with a deburring tool or fine file.
2. Remove all chips from inside the tube, especially from the inner ribs that hold the fittings.
3. Wipe the cut end with 90% isopropyl alcohol and let it dry. Do not use acetone or strong solvents on the painted surface.

Touch up the finish

Small scratches or bare edges near the cut can be touched up with black matte spray paint. You do not need to spray the tube.

1. Spray a small amount of paint into the spray can's cap.
2. Dip a cotton swab in the paint.
3. Dab it lightly onto the scratch or bare edge.
4. Let it dry. Apply a second light coat if needed.
5. Keep paint off the inside of the tube where the fittings go.

Recommended paint:

• Home Depot: BEHR PREMIUM 12 oz. Black Matte Spray Paint and Primer (B002144)
• Harbor Freight: Rust-Oleum 12 oz. Flat Black Acrylic Enamel Spray Paint (67938)

Check the fit

Dry-fit each fitting before bonding. It should slide in fully without forcing. If it binds, check for leftover burrs or chips. Then follow How to Bond Fittings to Black Aluminum Handrail Tubing with Epoxy.

When to get help

If the cut is not square or a fitting will not seat, contact us before installing.