Square tube welded so it in a diamond shape advice

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I have a customer who wants us to make them a square tube railing, but with it turned so the end looks like a diamond and the top is a point rather than flat. I attached a picture has anyone else ever done a railing like that before? it seems to me  like a lot more work, any advice I would appreciate. Attached Images
Reply:My $.02 is to simply cut a v notch into the top of the posts on a vertical band saw for the top rail. For the bottom, your simply rotating the material 45 degrees then welding to the post. Are there any more components to this railing other than what is shown?
Reply:You could use a Curve-O Mark tool to lay out the cuts or make a pattern out of wood or steel to trace your cut lines.  Then take a 6" waffer wheel in your Matabo and cut the notches.  That's how I would do it any way.  A porta band may work if you can hold the tubing in the right position.  Maybe even build a jig to hold the posts and cut them on a vertical band saw.Dan D.
Reply:That was only a pic to illustrate the position of the square tubing, It has twelve  16" verticals  and the railing is in two sections 1 at 16' and the other at 24'.I am in a unique situation, where I inherited a portable welding company,
Reply:If all the vertical pieces are squared off like the one in the picture then it's not too bad. Either way looks like the vertical band saw is the way to go.
Reply:Would he allow larger tube size uprights ? Then you could butt the diamond shape to it. Depends on tube sizes.
Reply:Someone posted here before of a bunch of headache racks and stuff he has built using square this way. I don't remember who it was but maybe he will see the thread and post. Like mentioned I don't think it would be that hard to just cut V's in the tubes for fitment.
Reply:Yes,  I have done many rails/several hundred feet like that.  I would look to find ways to not extend through.  If you need to extend then use flat bar rather than tubing or weld on both sides. Your real issue will be bevel / pitches, because hole changes shape. Depending on thickness of metal when you extend through at a bevel the flat edge will be plainly visible unless you cut your hole at an the angle of pitch. Cutting on a pitch is another issue.  I have a fixture that shifts and holds the parts 45 degrees for sawing at the appropriate bevel. Also, corners might be issues.If exterior rail, then it needs to be sealed.  So welding around should be acceptable.Last edited by tapwelder; 03-20-2013 at 09:48 AM.
Reply:One issue: The piece that's at a 45 degree angle is going to be wider than the straight piece.For example, if you use 1" square tubing, the piece that's at 45 degrees will be over 1-3/8"across the corners, so you'll need to grind/bevel/blend/whatever to get it to fair into the 1" wide piece.
Reply:Originally Posted by KelvinOne issue: The piece that's at a 45 degree angle is going to be wider than the straight piece.For example, if you use 1" square tubing, the piece that's at 45 degrees will be over 1-3/8"across the corners, so you'll need to grind/bevel/blend/whatever to get it to fair into the 1" wide piece.
Reply:Assuming the post is slightly larger than the max width of the rails, I'd be real tempted to make up a template and cut the holes with plasma if they are thru holes and you have a ton to do. If you just need to notch the posts, I'd still be tempted to cut the V's out with a template and plasma, and do the side cuts with a portaband..No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:If this is a big concern you might try making a few test pieces, using some of the methods suggested here.   That might tell you a lot about whether or not this is going to be a big  increase in labor or not.   I liked the suggestion of a template for a plasma cutter, but I don't have a vertical bandsaw or a porta-band.As somebody said, just make sure that you charge enough to make up for the extra labor.  You could even quote it both ways, square vs. diamond.RichardSculptures in copper and other metalshttp://www.fergusonsculpture.comSyncrowave 200 Millermatic 211Readywelder spoolgunHypertherm 600 plasma cutterThermal Arc GMS300 Victor OA torchHomemade Blacksmith propane forge
Reply:The customer wants the verticals turned , and to add expanded metal in between the spaces, but there is more railing on each side . I like a good challenge, and the only way we have access to this area is a fire escape ladder, it is on the 3rd floor.I am in a unique situation, where I inherited a portable welding company,
Reply:and it has to be all in 2" square tubing.I am in a unique situation, where I inherited a portable welding company,
Reply:If it all has to be 2" sq tube turn the posts 45 deg also it will make fit up a lot easier. The other way it will look like c@$p at every joint.