Split 3/32" filler rod into two ~0.046" rods?

[Welderooni]

I have some excess 3/32 aluminum and steel filler rods and wanted to ask you gurus if any 'ol' shop trick exists that makes it easy to split a 3/32" thick filler rod in half so you get 2 ~0.046" thick rods? (Thereby, resulting in 2 thinner filler rods)?

The filler rods that are thinner than 1/16 make it much easier for me to weld on thin walled tube, so just trying to make use of what I have..

[DaveO]

The easiest way might be to find a guy with MIG filler wire and trade him your 3/32" for it, then chuck the .023 into a drill and combine two lengths into .046. But by the time you find that guy, or figure out a reliable way to cut 3/32, a roll of .023 from the Home Deep/Lowes/LWS/Harbor Freight might look pretty good.

[sportbike]

Yeah, I don't think you are going to find a reliable way to split 3/32 filler.

I'd keep the 3/32 on teh shelf for a larger project and go buy smaller rods or a roll of wire.

[DaveO]

2 pounds of .023 from Welding City is $10, free shipping. Considering the ROTEI (return on time and effort invested) that may be the smarter move.

http://www.weldingcity.com/filler-me...3-0.6mm-wires/

[Welderooni]

The situation is I have a lot of surplus 3/32 and the time, but not a lot of extra $ to spend. So, I don't mind building a rod splitter if it works well. How would you guys go about building a tool that perfectly splits a 3/32 rod in half?

[zoama]

The situation is I have a lot of surplus 3/32 and the time, but not a lot of extra $ to spend. So, I don't mind building a rod splitter if it works well. How would you guys go about building a tool that perfectly splits a 3/32 rod in half?

I just don't see it happening. Your best bet would be to purchase .040 or .045 mig wire in aluminum and steel.

[redbeard]

I wonder if rolling it would be easier than ripping it. Even so, it would still be less of a PITA to just sell your 3/32 and buy what you need. Or find somebody to trade with.

[DaveO]

OK, no cash but willingness to try, got it.

Step 1: At least try posting on CL or welding web or somewhere: have 3/32, want to swap for 1/16th TIG wire or .045 MIG. Welderooni, what's your location? It's not in your signature.

What about: pounding the 3/32 on a vise or anvil to flatten it out a bit, then get after it with a monster set of tin snips to cut it in half? My hands hurt enough as it is, can't imagine doing this myself. One concern to this idea if it's at all even possible would be inclusions or embedding extra junk in the process of hammering.

[Rambozo]

You would pull it through a drawing die to reduce the diameter and increase the length. That was how it was made in the first place. The aluminum won't be too hard, but the steel will take some serious force. Just not very practical to do, unless you already have, or have access to the setup for that.

[geezer]

There is a solution,,,it's called money,,,get some and buy the proper dia rod,,,splitting filler rod,,,thats the best laugh I have had in some time..
i,m not sure what an hour of your time is worth...but one hour of mine will buy a lot of proper dia rod.

[Rivets]

Maybe a long shot, but it's what I would try.

Hang one end of the filler rod from an appropriate support.
Attach weights onto the other end thereby stretching and slimming.

If it works, let us know.

rivets

[sportbike]

Find someone that is an experienced sword swallower AND has a gap between their front teeth.
Have then swallow the rods, then hold their jaw shut, grab the end of the rod with vise grips and give it a pull.
If it doesn't give you the proper size, look around for a different front tooth gap width and try again.