...that my Steel(s) have arrived for the seam remover and the rack support struts.
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So I had another go at it and what a difference!
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The seam appears to have been removed and no damage done to self or tooling.
And here is the slug with the HSS tool steel at the exit end of the tube having been pulled all the way through.
So would a 35mm tube now just slip in there smooth as silk? Errrr.....Nope!
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It is good to remember that all tubing sizes are "nominal" sizes and there can always be some variation.
Undaunted, I took a piece of 35mm Square tube of 2mm wall thickness and attacked it with the "nominal-size-adjuster" on all 4 sides progressively in rotation until with a metallic "pop" it began to slide in.
After several more goes and some "polishing" with emery cloth and a wire cup-brush I was able to shove it in both ends to a depth of 10-Inches. Most satisfying I am sure you will agree.
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Here she is with both ends stuffed with 10" of adjusted metal tube. Yay! Success.
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Taking the size of the inserts down by maybe 0.5mm overall on all 4 faces will just return the tube to the same thickness as the outer tube. I do not believe strength will be significantly compromised.
I am quite pleased to get the result I wanted.