Cutting Crew 2: Electric Boogaloo

In the last post we looked at a range of manual techniques for cutting glass tubing. Most of these rely on creating a scratch in the glass surface which then allows controlled cracking and separation of the ends.

It’s always easy to apply these methods to straight, unbent tubing and for this type of job these techniques are all that is needed. Sometimes however, it may not be possible to break the tubing in the conventional manner, either because it is awkward or impossible to get good leverage on the tube to snap it, or because the length of glass to be removed is just too short to be snapped. Trimming electrode doublebacks, or to make welds for continuation tubing are common cases where a different approach might be required.

In this post we’ll look at the design and build of a simple hot wire tube cutter for the neon workshop using common off the shelf parts.hwtc-1

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Cutting Crew

Glass is a tough material that shows excellent strength and resistance to breakage, but this all depends on the integrity of the outer surface. An imperfection, scratch, or other break in the continuous surface of the glass can be made to spread and eventually cause the glass to break: the difficulty is in making this a controlled process that yields a clean, square cut without jagged edges, cracks, or chips.

Cut glass will typically need to be welded, either to an electrode or another section of tubing and this is most reliably performed when both pieces of glass have cleanly cut surfaces.

Many tools are available to cut glass in various forms. In this post we’ll concentrate on tools that are useful for cutting the types of tubing used in neon work. Diamond styli and wheels are common tools for cutting glass sheet but these have little use in the neon shop. We’ll run through the different types and their use, and the proper technique for splitting the glass.

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Tools for glass cutting (left-to-right): mill bastard file, laboratory glass knife, plastic glass knife, diamond file, circle scorer

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