Like many others I don’t have a shop to play with my bike; I’m relegated to sharing a 2 car garage w/ 2 Jeeps and a ton of crap.
That means I don’t have large tools like a drill press, lathe, sander, etc.
If you can think of a better way to trim 1/2” off of this 4” diameter ABS cap than a hacksaw and file, please offer up your suggestions.
I’ve got a skilsaw, but …

 

Use a flap disk on an angle grinder, then finish it with sandpaper on a table.

 

Why not a hacksaw, just rotate it as you cut.

 

The hack saw would make a nice clean cut.

If you have a hose clamp you can put around it to line up with what looks like a line you scribed to use as a guide to assure a straight cut.

​​​​​​Then you need to clamp it.
if you have a vise you may need to find something to fit tight in the inside diameter to keep it from compressing in the vise that doesn't interfere with your cut.
​​​​​​wood jaw protectors on vise so no damage. Maybe even a rag or some tape over it for protection.

Maybe go a bit below your line and finish by lapping on sandpaper on a flat surface

 

scribe it all around by putting it edge down on a flat table, then use something to hold a grease pencil 1/2" off the table, then turn the plastic in a circle against grease pencil.
Then use a dremel with cutoff wheel, then file edges.

 

All great ideas so far, guys.
The only reason I haven’t already used the hacksaw is because I was hoping for a way I hadn’t considered, that’s all.
My vise will open that far & it has soft-ish jaws.
Yes, I scribed a line on both the ID & OD as a guide.
i like the hose clamp idea and it will be part of my final solution. 👍

 

You just need to open the jaws up to steady it, put it in 90 degrees to the opening, Hold it with your hand, and just go like 1/4 way thru on your mark, rotate, repeat. Till you get around, then finish the cut thru. All I can say.

Why you worried on the cut, this a special application after the cut.

 

I have used a cheap harbor freight grinder for many cutting/grinding projects.
The tool is very loud and ergonomics are not great but it is a work horse item that gets used.
I believe it is about $15 for the grinder. The grinding wheels are a $1 or $2
On small tubing stuff, I just grind down the piece to size wanted instead of cutting around.
It works rather quick and the tool is easy to store...gets used numerous times a year.
If that grinder is out of your financial budget and you already own a drill then a drill sanding disc attachment with the sanders is about $10.
But the grinder is more useful.
Always wear eye protection and move far away from anything just in case something goes flying.

 

It’s not really all that special, but I figured there’s got to be a way to make it look like I tried to not do a shitty job with the same or less effort.

I’m making covers for the exposed components on my bag lid speakers.
These fit perfect, but are too tall..
If I trim off 1/2”, I can use silicone (or similar) to secure them to the back of the grill arms, while also keeping them as tight to the magnet as possible. Essentially, they’ll take up less space in my saddlebag and I can’t leave **** alone.

 

Yep, hacksaw will do that, just a forward stroke on your mark partially till you get around, then go around again til you get thru. You only have two to do, piece of cake. Silicone will fix the rest. Then post your finished job.

I have something similar to this that would work for you. Just thought of this.......

https://www.lowes.com/pd/Capri-Tools...saw/1002324446