I'm trying to Flatten 2 inches of the end of an Aluminum pipe - Without it cracking.

What's a method? Heat?

Too much depends on the alloy its made of, but I'm no expert.

Kinda like different steels, soft wire you can bend back and forth and it won't break, but the next you can't bend in a 90 until it breaks.

What grade aluminum are you working with, Scott? If you don't know, it’s a crap shoot. You can try heat. Either put some soot off an acetylene torch, straight acetylene, or a black magic marker, and heat with a big tip till the black leaves, then press. If you don’t know the grade, and you need to weld it, it’ll be a double crap shoot!

If it breaks that way, you prolly have either a 200 series alum, which is alloyed with copper, or a 700 series which is the same, but harder that they machine a lot of aircraft parts out of. 6061-T6 which welds good will crack like that if cold worked with the grain.

My guess is to anneal it like you would brass. Heat and put in water.

I'm trying to make a flattened end (slot) to slide in a Sawzall blade -drill two holes to small bolt the blade inside the slot . Building a lightweight saw that the blade slides into for portaging and put together to cut Firewood i
While canoe camping.

The silver one cracked easier, but it's the one I need to work with .

Can you make an insert instead of flattening it out?

That type of material looks like the brittle cast stuff like scout said slot the center and bolt it maybe less stress if it even holds up.

The gold has been anodized then pressed, the other is not anodized and will crack and break when trying to flatten it out

You may try to apply heat in a manner to not melt the material on the gray pipe, but doubt you will get a sufficient
amount need to anodize with out a controlled oven

Your best bet is to notch a round piece of wood for the blade then force the wood dowel in the open round end of the gray tube then drill two holes and place two bolts in and tighten them all together as one piece.

Thank You. I'll try heat. Then if that fails I'll try an insert

The gold tube cracked when flattened in one side...but I was able to cut UT offand use it.

But the silver is larger and I need to use that.

Slide the gold one inside the silver, epoxy.

I need the interior of the silver one to hold the blade(s

Sand/grind the sides off the gold one then attach the blade to it, then epoxy it in the silver one. Push the flat part clear inside the silver one.

Make it out of wood. Not much heavier and will float when you inevitably drop it in the drink!

How long does the "saw" need to be?

Other then the fact the tubing is probably free, theres numerous folding saws that take sawzall blade, and theres small bow saws that would cut way better then a sawzall blade.

The Handle is/was- if I finish it ; supposed to hold the blade inside with a spare 12" Diablo pruning blade.
16" handle 12" blade

Truth be told I saw a you tube video of one using that blade / And I thought "I can do that better"

I was about to Buy a "Silky" saw and want to Now Again

I would haul a small bow saw. I bet it would not weigh a half a pound more and it will cut much better.

Can you switch out the whole thing to PVC if it's just a saw handle? Or is that what you already have without buying different. Little hockey stick tape on PVC can make nice handle for somethings.
Just an idea.

Mac

I've used the best BWCA bow saws/ since 1973 as a kid till Now

I really dislike bow saws

Hard to beat a Silky

Drive to FL and I will give you one to use

WS