![]() Other suggestions I will offer would be to get as thin an abrasive blade as you can. ![]() I like to do the 45 joints as they are much more asthetic. Since I use a dry cut saw, angle cutting on any of the square, round, rectangular & angle material is quite easy and very accurate. ![]() I use my combo square every time I make any changes, especially with odd angles. I will also concur with Mac regarding using a square to set the proper angle alignment of blade and vise jaws. Here is a good video by our own Rocky D that shows you how to cope the joint. If I want an angle, other than 90, I will make a jig. Once I got my cheap piece of junk HF chop saw set to 90 and cutting well, I figured that is pretty much where its gonna stay. It is much easier to fit it together and weld it nicely this way. I made the first cuts with the chop saw, then finish it with either my hack saw (if you don't have a lot to do) or a zip disc on the angle grinder. Oh yeah then, there was the few I cut 1/8" too short, but its all good learning. It took me a couple of hours to cope all the joints on some 1.5" angle iron I am building for my new Thunderbolt cart, but I have never done it before, and I had to watch the video a few times. It takes a bit longer than just hitting it with your chop saw, unless of course your chop saw is hard to adjust like my HF one is. The best thing to do is what I did today - Instead of mitering them, cope the joints.
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