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Old 05-17-10, 05:49 PM
  #8  
FBinNY 
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Join Date: Apr 2009
Location: New Rochelle, NY
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Bikes: too many bikes from 1967 10s (5x2)Frejus to a Sumitomo Ti/Chorus aluminum 10s (10x2), plus one non-susp mtn bike I use as my commuter

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The tool of choice is a hacksaw with 24-32 teeth per inch. If you're lousy at straight cuts you can use a pair of hose clamps on either side to make a guide on a fairly straight section. On curves use the hose clamp on the good side only as a safety so you don't accidentally cut too short.

Use a half mill file to clean up the ends and round the outer edge off a bit for safety. If your cut is really bad use a mill bastard (fairly coarse file) to get close to the line then finish with a half mill file.

Tubing cutters may be OK in on straight sections, but the rollers can't negotiate the inside of a curve, so they're probably unsuited to the task.
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