How to Join Square Aluminum Tubing

What You'll Need
Square Tubing Connectors
Square Aluminum Tubing
Rubber Mallet
Metal Finishing Pad

Square aluminum tubing is primarily used for support or frames of various structures such as racks and cabinets. They are used because of their convenience in installation and un-installation. They are very handy and can be packed and be brought anywhere due to their portable nature. They therefore need to have several points of connection in order to be disassembled easily.

Step 1: Measure the Aluminum Tubing

Before even joining aluminum tubing, you have to determine the appropriate lengths of each section of tube. When you’ve determined the length you need, clamp the tubing using a pipe vise for square pipes to hold it steady. Cut the tubing using a hacksaw.

Step 2: Sand the Tubes

Once you’ve cut the tubes to the desired lengths, the cut portions will have sharp and jagged edges that may be quite hazardous and could cause injury. Sand these portions and smooth them out. Use a metal finishing pad to accomplish this.

Step 3: Fitting the Tubing into the Connector

Grasp the tubing firmly and push the connector onto one end. You may not be able to fit it all the way through but that’s okay. It has to be very snug. Get a mallet and start hammering on the connector so it’ll go in all the way. Do this to the other end of the tubing.

Step 4: Removing the Connectors

In the event that you need to remove the connectors to detach joined tubes, use the mallet to hammer the aluminum tube out of the fitting.