Blinkybug (Maker Faire version)

Step 3 Prepare the copper tubing

The copper tubing is cut into 1 1/2" lengths (1 piece per bug). This will act as the guitar string / antenna "guide," so the guitar wire must fit through the tube after the pieces are cut. This turns out to be tricky as it's very easy to block the tube opening when cutting. I find that my Dremel tool does OK most of the time, but on many pieces I end up bunging the thing up. Wire clippers definitely do NOT work, as they unfailingly crimp the ends closed.

Measure and mark the copper tubing at 1 1/2" inch intervals. Now carefully cut the copper tubing with your rotary tool... of course while wearing eye protection as little copper bits will be flying every which way! Set it at a high speed, and let the tool do the work... don't force the tubing against the cutter.

I tried this with a hacksaw with little luck... maybe you'll do better! For the Faire I'm getting them pre-cut at the factory to bypass this trouble.

Finally, clean up the cut ends with a metal file.

Comments

[Kiteman]

Have you thought of puting something inside the tube while you cut it, to stop it closing up? Say some narrow pin or nail?

[monkeychow]

A sharp craft knife works very well for this step. Roll the tube back and forth under the blade and score it all around with even pressure. Credit to the gent in the local hobby shop for the tip.

[SFHandyman]

That's the way a pipe cutter works. It rolls a round blade around and around the tube until it separates. My Dad (a carpenter) taught me to just hold a thin tube or wire against a pocket knife blade, and run the blade around and around the until the insulation is cut, or the tube separates.

[obeyken]

that's a good idea! thanks! i'll play around with that...