I am using profiled linear rails. I bought them from ebay because they were cheap, and I was expecting to be able to cut them down, as they are about an inch long for my setup. After holding them, I began to wonder if they are too hard to cut with the bandsaw. Today, I tried cutting one with my bandsaw, and after about a minute sitting there with the teeth just gliding across the rail, I stopped, and noted that the blade had barely cut .5mm into the rail, on the corner! I did this on the back of the rail, so there are no worried about them being damanged as far as usability.

And, the frame of my machine is already built and permanently together, and won't easily accomidate the extra ~1.3" in the rails (these are the y-axis for a gantry). A redesign or starting over could be done, but obviously that would be more of a last resort (especially starting over!).

So... how do you cut linear rails? It doesnt seem like anything will use it that doesnt get hot. Ive never had my bandsaw get stumped like this, and I even just sold my chop saw! A chop saw would work, right?

Use an abrasive blade like a chop saw. This may soften the surrounding area, so if that concerns you then wrap the area close to the cut in a water soaked rag and stop every once in a while to re-wet the rag.

Scott

You can use the abrasive blade in a circular saw, it won't be easy to keep it perfectly square but it will get the job done without breaking the bank.

Find a machine shop in your neighborhood, and ask them to cut them.
They may charge a few dollars, but at least it will be done right!

Most all machine shopd have an abrasive cut off saw which will cut hardened steel with little effort.

If you can't find someone to do it, ship them to me and I'll do it for $20

Widgit

I just took them to Ace Hardware since I knew they had a chop saw for cutting pipe. Im in there a bunch so they let me come back there. Worked great!

Thanks!

Now, time to finish the frame and start mounting the hardware.