Semi-production cutting

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I need some voices of experience!I bought a Rage2 cold cut chop saw for cutting DOM tubing. I will be making a couple hundred of 1.5" (in length) cuts per month so I have termed the need 'semi-production'. Of course, I waited an eternity to get the saw - and when it finally did get here - it was banged up and the base was bent. Wouldn't even sit flat on the work bench. That said - I also noticed this saw has no visible means to bolt her down to the work bench.After reading through some of the other threads on chop saws - I am now questioning if the Rage2 is the right tool for the job.  FWIW - I was not impressed with the handle on the Rage2. The location of the power button means some upper arm/shoulder contortion-ism!All told - on a monthly basis - I'll be making about 300 cuts @ 1.5" in length in the DOM tubing, and additional 300 cuts @ 18" in length in EMT tubing. The cuts need to be as square as humanly possible.Budget is $500.  Experienced advice would be greatly appreciated!Last edited by netxtown; 09-11-2012 at 08:01 PM.
Reply:I am not familiar with the saw, but I would figure a way to fasten  it to a table and simply  setup a adjustable stop.If you cant fix it with a hammer, it must be an electrical problem."Boy, everyone starts with a full bag of luck and an empty bag of experience. The trick is to fill the bag of experience before the bag of luck is empty."-Grandad circa 1990ish
Reply:I agree, set up a stop. My bandsaw has a factory stop and I use it quite often. If it didn't have one I would have made one for it long ago.
Reply:From stuff I am reading, a horizontal band saw may actually be the better tool for what I am needing to do. I like the idea of setting it up and letting it do the cutting instead of me holding the handle. Yet, there seems to be no end to low ratings from buyers of units in the $500 range.I got to have good square cuts as the product is a steel post for the hobby industry in which pieces are screwed together to extend its height. (a collar assembly is welded together, inserted into the pipe, and then screwed down) Hence, the need for tight square cuts...and lots of them....to produce a straight post.Guys, am i barking up the wrong tree altogether?? Is there a better forum out there for advice on tools for a small scale production environment?
Reply:I like my Dewalt dry cut saw.  One of the marketing points that attracted me to it was Dewalt's statement that the base was meant to be welded to for custom fixtures and jigs for repetitive cutting.  I'm not saying it's the best, but it is right at your $500 mark.DeWALT DW872http://www.dewalt.com/tools/metalwor...aws-dw872.aspxLast edited by el bob; 09-12-2012 at 11:44 AM.Reason: added model name and link
Reply:I have the Milwaukee 6920 dry cut saw.    I've been thru 3 blades on it and am absolutely thrilled with the cut quality and performance.    I do a LOT of semi production.Blades last about 1500 cuts before they're making sparks not chips.
Reply:300 plus cuts? You should look into hiring someone with an automatic band saw or a cutoff lathe.Maybe try a bandsaw and bundling the material? You might have trouble getting good cuts on the emt with a CTC saw, they tend to tear out the back on thin wall tube.Ian TannerKawasaki KX450 and many other fine tools
Reply:Originally Posted by fortyonethirty300 plus cuts? You should look into hiring someone with an automatic band saw or a cutoff lathe.Maybe try a bandsaw and bundling the material? You might have trouble getting good cuts on the emt with a CTC saw, they tend to tear out the back on thin wall tube.