45degreeing angle!

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I need some help cutting 45's and matching them up. I started cutting my angle getting ready to build my cart. I then started cutting the 45's with my chop saw. I started to line them up to make sure it was all gonna line up right. They don't match up at all. I am doing something wrong but I don't know what. I need some pics or something. Like I said my chop saw has the adjustment for the miter's but you have to flip the other end around to cut it. It just ain't working out.
Reply:Put a square on your guide and see how far off it is, you might have to make your own guide or at least tweek the factory one.Anything worth doing is worth doing RIGHT
Reply:Or draw a line with a tri square. I use a metal 12" combination square It also has a level in it. DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:yep, read here about many problems with accuracy when cutting with an abrasive wheel on a chop saw, seems that the clamping/angle adustment on these saws is really crappy.  It may take some modifying of the vise arrangement to hold the part securely at a precise angle, and some finese to feed the blade without deflection.  Still better than doing it freehand with a saws-all, that's where I'm at with home projects.
Reply:Do you cut through both sides of the angle or just 45 one side? Do you understand what I am saying? Yeah definitely beats freehand with saws-all man.
Reply:One piece at 45* gets you 45*...two pieces at 45* each gets you 90*Is that what you're asking ??Anything worth doing is worth doing RIGHT
Reply:O.K. a 1.5" angle is 1.5"x1.5". Do you cut both pieces at the same side or do you leave the one 1.5" piece straight cut and miter the other 1.5" piece. Kinda hard to explain lol. Do you put the angle in the saw and cut across both 1.5" pieces or just miter one 1.5" piece. THX LOL
Reply:Well, I'm lost now...lolAs an example, if I want to build a square I put 1 piece in and cut it at 45. I then lift it straight up and turn it 180 degrees so the uncut end is now at the blade, flip it over and set it back in, position to my mark and cut it. You now have one side of a square completed.If this doesn't make any sense I'll let someone else try because I can show you but don't know how to explain in type it without a drawing.Anything worth doing is worth doing RIGHT
Reply:I think you answered it for me. What I am looking for is: A piece of angle is like 2 halfs joined. Do you cut through both pieces? When you lay the angle in the saw to cut. There is a top and bottom. Do you cut through just the bottom half of through the top and bottom half. If this dont get it NM i'll need a pic LOL Thx.
Reply:Cut one peice at a time.Be the river, Baby!
Reply:There are left cuts and right cuts to make a square, 4 pieces.You can cut clean through which will give a closed end joint. Or you can clip the 45*s off of your 4 - 90* pieces leaving a square edge to make an open joint which can be closed nicely when welding it together.  I use the open end joint because they are stronger, easier to clean up and leaves a clean inside edge.One piece at a time, chop one end at 45*, turn & flip and chop the other @ 45*.  Or, you can just reset the saw to the other 45*, sllide it down and make the second cuts.Don't ever attempt compund angles for crown molding, it gets a lot more confusing from here.Hobart 140 Handler w/ gasHyperTherm Powermax 380 Plasmaoxy/acetylene
Reply:Re-reading you last post, I think you may be laying the angle down in the saw with both sides touching the table (?).  You have to have one side up against the back, and one side on the table so it's is in the 90* position.  If you just layed it in the saw, you could never cut it right.Hobart 140 Handler w/ gasHyperTherm Powermax 380 Plasmaoxy/acetylene
Reply:I was taught that angle iron should be notched for 90* joints.like this: Attached Images
Reply:No I am laying it in the saw right and I know there are left and right cuts. Like in the pic above. The piece of angle that is notched. Would you just 45 that piece or would you 45 through both pieces. Or can you do it both ways? I think that is what you were referring to in your reply. Would you have any pics possibly? Thx. And is there anything wrong with notching like the way in the pic?
Reply:Not trying to be a pita, just dont wanna screw up the metal that I bought and have to buy more cuz I couldn't get the damn cuts right. I appreciate all the help.
Reply:Notch joints are the strongest with 3 different directions of weld support. They just take a little extra effort to make as they can't be whacked off on a chop saw.Trying to answer your question, instead of the male/female notch ends, just 45* both pieces, one at a time.  Can't make it any clearer than that.Hobart 140 Handler w/ gasHyperTherm Powermax 380 Plasmaoxy/acetylene