miter or butt

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Want to build a fence. 4 ft x 8ft panels 1.5" square tubing, with an piece of angle across the top and bottom (inside) to attach wood inside (cedar or cypress).I'll set up a jigShould I miter or butt the corners?31 panels 3 gates...Should I drag it across town (an hour or more one way) and use my buddies mitering band saw or use a chop saw?will paint black, stain wood first....Should I use primed steel ?14 ga ok for 1.5" square tube?3" post ok?4 x 8 look ok?Leave gaps in the bottom to let water out? or drill some holes?Search is not working..Millermatic vintage with a nice shop to work in.Thanks Andy
Reply:14ga is fine for the tube thickness.  You can use 16ga for the top and bottom rails and pickets and be just fine.  14ga is fine for the posts.  3x3 is overkill for posts but will be just fine.  2x2 will be fine too for posts.  Use galvanized tube to keep it from rusting, weld with fluxcore wire, paint over the welds with cold galvanized spray, then prime and paint with Rustoleum gloss spray of whatever color you like.When I build fence panels, I don't put sides on them, as the posts will be the sides.  I build the panels with open ends, set the posts, then weld the open top and bottom rail ends of the panels to the posts, trim the posts to even heights and put caps on the post tops.  No mitering needed, a chop saw is all you'll need.Last edited by DesertRider33; 09-20-2010 at 08:40 AM.MM350P/Python/Q300MM175/Q300DialarcHFHTP MIG200PowCon300SMHypertherm380ThermalArc185Purox oaF350CrewCab4x4LoadNGo utilitybedBobcat250XMT304/Optima/SpoolmaticSuitcase12RC/Q300Suitcase8RC/Q400Passport/Q300Smith op
Reply:The only time that it's really worth mitering joints is when the ends in question would be left open with nothing covering them.depending on the chopsaw you own, you can use them to cut miters!  I wouldn't worry about using primered steel.  I'm sure that a 3" x 3" post would be fine, I am unsure of the norm.  I guess what I'm getting at is either draw or build one section and post a picture.
Reply:Well lets see if this loaded, this is a dumpster gate near here. Early AM an phone photo sorry.I don't think I'll use a wood cross brace and only 4 ft tall. Attached Images
Reply:They just put tabs on the back and fastened a 2x3 wood fence rail, then nailed the wood to it. I'll need to sandwich my wood or screw to an angle.They use plastic caps on the tops of the style, the rails are covered by a but weld.I guess if you grind em smooth the look of a butt or miter won't matter, I don't guess strength will be an issue.So, that leaves production ease.Thanks Andy