At Connect-it, we don’t just build strong frameworks — we empower creators to overcome challenges with practical solutions and a mindset that’s wired for innovation.
One common obstacle faced in DIY and professional projects is tight fitment. You’ve cut your aluminium or steel tubing, but when it’s time to fit the connector… it’s just too snug. Here’s why that happens, and what you can do to fix it fast — without compromising the job.
💡 Why It Happens
Our connectors are engineered to international sizing standards. For example:
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25.4mm (1 inch) tube with a 1.2mm wall = 23mm internal diameter
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With a 1.6mm wall = 22.2mm internal diameter
➡️ 0.8mm tolerance range
Same goes for 50.8mm (2 inch) tube — tolerances stay within 0.8mm.
But not all steel mills or aluminium extruders stick to the script. Manufacturing inconsistencies can make a tube slightly undersized or oversized — just enough to affect fitment.
🔧 What You Can Do
1. Pre-Check First
Always test your connector on the tube before cutting.
👉 It should not take more than 3 mallet blows to fit securely.
2. Too Tight? Lighten It Up
No stress. Just use:
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An 80 or 100 grit flap-disk (with safety gear!) to lightly sand the splines of the connector.
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You can also hand-sand with 80 grit if you prefer.
3. Choose the Right Connector
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GREY connectors: Softer compound, ideal for aluminium
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BLACK connectors: Tougher, reinforced with 30% glass fibre — made for steel or stainless
💬 Our Philosophy
“When you can’t control what’s happening, challenge yourself to control how you respond. That’s where your power is.”
Every project has its moments — but every creator has the tools, skills, and mindset to overcome them.
Keep innovating. Keep shining. We’re all born to create. That’s where your power is.
