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Secret to cutting square brass tubing without crimping?

I ordered some K&S square brass tubing with a Rigid tube cutter.  No matter what I do, I always seem to compress the tubing -- and I need to fit it over a smaller tube.  The tool is also very difficult to use on the square tubing.

Any tips for cutting square brass tubing without crimping?

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I know if you pack sand into tubing you can bend it without crimping. You could try packing sand into an offcut of tubing and see if that works?

Hi

Cut it with a small hacksaw, hold it in a vice with square jaws, and cut close to the jaws. I'm not sure what you mean by a rigid tube cutter, but a hacksaw is best I would suggest.

If you don't hold it in a vice, you'll just compress it, the jaws of the vice prevent lateral distortion. If you don't have a vice hold it against something rigid.

Hope this helps, I've spent the afternoon doing exactly the same thing.

That does help.  Thank you both.

I also use a hacksaw, but apparently the best way is to use a Dremel with a cutting blade.

It is also important to have a small square file to be able to clean up the inside of the tube. Then it will fit nicely.

I cut brass and aluminium tubing on a bandsaw.  No special hacksaw blade, just a wood cutting blade.  Then it does take a bit of cleaning up with a file.  But if I didn't have a bandsaw or a Dremel, I would use a hacksaw.

Piercing saw!
It's an extra tool, but not too expensive. Also called a jewellery saw I think. I use it a lot since I bought it. It makes very clean cuts. No crimping, no noise, and very minimal cleaning up to do afterwards.
Hacksaw works fine too. If you are going to do a lot of metal/brass cutting in the future, I could definitely recommend getting a piercing saw.

A bench top mini cut-off saw is small, fast, and easy for this task.

2" Bench Top Cut-off saw, 120 volts.  It's an extra appliance, but if the blade is fresh it makes a very clean cut.  If the blade is less fresh I have to file inside to be able to fit in a small brass tubing section.

Just wanted to follow-up.  I wound up purchasing a piercing saw with some #3/0 blades (and a vice).  I've had zero crimping.  Thanks for the suggestions.

If in the US, you really can't do better than the Harbor Freight 2" benchtop cut-off saw. It is the very best bang for your buck. I probably use it more than any other single tool.

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