Cutting a Carbon Fork Stem

[S6PNJ]

Having taken the plunge and bought one of the Westbrook Cycle's Scott CR1 frames, I now need to cut the front fork to length (or over length first). I've read various threads about cutting at home with a hacksaw (32 tpi) but I'm wondering if I can get away with using my fretsaw. I have some very fine toothed blades and as long as I keep the fork square to the table and blade, I should be able to cut it accurately. I know I need to keep the carbon fibres at bay and will wrap some masking tape around the fork before I cut and possibly even spray it with water to dampen any carbon dust.

Any pro's and con's to my method? I'll am to cut the fork to leave a good 10mm (2 spacers) initially and then see what happens to my ride position as I lower and raise the stem position. I have measured my old (current) bike so I also have that to work from as a first rough guide. Any other advice?

[Roman]

I always use a hacksaw and mitrebox. Takes 2mins, more control, less dust, less chance of the blade bending, snagging or snapping than a fret saw.

Edit to add: Dust mask & eye protection as well as water & tape!

[S6PNJ]

I should have amplified my post a bit, my fretsaw looks like this


Rather than like this

[Roman]

Does yours have an accurate feed mechanism to keep the work straight? (mine doesn't!) They're great for freehand cutting of tight complex profiles and fast shaping, just not my first choice for an accurate straight cut on an expensive piece.

[Rocksteadyeddie]

I did mine with a hacksaw and a vice. Outside with a mask on. Not much dust as the "shards" were much bigger than that. Worked fine.

[S6PNJ]

Roman said:

Does yours have an accurate feed mechanism to keep the work straight? (mine doesn't!)

It doesn't but I would knock up a suitable fence and use a set square against the fence to keep it straight as I feed it into the blade.

[S6PNJ]

Rocksteadyeddie said:

I did mine with a hacksaw and a vice. Outside with a mask on. Not much dust as the "shards" were much bigger than that. Worked fine.

I have a junior hacksaw and a B&D workbench as a last resort (other than the local bike shop as the last last resort)

[Rocksteadyeddie]

Seriously it's not that hard. Much easier to cut than aluminium, and it ain't asbestos (albeit not sure you want to be breathing loads of it in).

[Roman]

Let us know how it goes and best of luck then!

[BadgerBenji]

Saw guide blocks are on ebay for £15 much cheaper than botching it, and it's one of those items you put away in your toolbox and wonder if you will ever use it again, and you will, great as well for cutting mountain bike handlebars neatly.