Lathing Outsize Items

[bingbangbong]

Hi there, I'm Paul from N Ireland, this my first post!

I would appreciate any wisdom you can offer, I have no lathing experience I'm ashamed to admit, but I need to achieve a finish and I can't think of any other way to achieve it.

I have a need to round off the ends of aluminium tubes in 50mm (2") and 75mm (3") diameters. The tube walls are 3.2mm thick and the roundover needs to be 3mm (1/8") radius to meet safety standards. The lengths of the tubes vary greatly but the 2" tubes won't be beyond 1100mm (43"), the 3" range from 1400 (4'7") to 1900mm (6'2").

I have to make 100+ of these every month and I'd like to find a way of doing it consistently and quicky. I visited with a local machinist who had large machines that could handle the 2" but I've yet to get his sample after several weeks and I'm wondering if it is something that I can set-up as a specific dedicated machine in my workshop.

My experience of some things is that the concept may be simple but the execution is complex. I'm hoping this isn't one of those!

I'm fascinated by all kinds of fabrication and work with a variety of processes but I'm completely naiive about lathes so I'll happily go get the long wait & the spotted paint, no worries :)

I appreciate your help and suggestions.

Many thanks

Paul

[aametalmaster]

I would use a long bed lathe and a steady rest. Then grind an HSS tool bit to suit your radius. Alum should cut real nice. But the length may be a problem unless you can grip them on the inside and cut on the chuck end...Bob