need help setting up a cut on a chop saw

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hi-this forum has been super helpful to me so far and i hope that maybe someone can help me with this one.  i'm making a bumper for the rear end of my truck and i'd like to have it wrap around the rear quarter panels.  obviously, i need to make a 90* turn.  aesthetically, two 45* turns look better but there is a gap between the flat face of one side and the cut end of another.  therefore, i had planned on mitering both ends of the stock to 22.5* so that they butt up together nicely but...i'm having a hard time setting up my chop saw to cut this angle.  i know better than to use the fence as an absolute guide so i have a speed square and a protractor to trace the angle i need on the stock first.  the problems are: clamping the metal and the material (2"x4"x1/8th) not quite fitting under the saw.  the cut needs to be made with the 2x4 on its long axis.  if the saw blade beveled, i'd be golden, but it doesn't.   oh, the saw is a standard 14" saw.  i'd love to get a bandsaw for other stuff; would this cut be easier to make with one?
Reply:Originally Posted by racerwad...the cut needs to be made with the 2x4 on its long axis.  if the saw blade beveled, i'd be golden, but it doesn't.   oh, the saw is a standard 14" saw.  i'd love to get a bandsaw for other stuff; would this cut be easier to make with one?
Reply:I always cut a scrap piece of wood on the miter saw, or table saw and use that as a guide for the chop saw.  If you don't have one find a friend who does and cut some wood templates and label them for popular angles 22.5, 30, 45 etc..  Makes quick accurate setups!
Reply:well, i just so happen to have a wood miter saw and i've thought of making a template.  mac-  i like your idea but again, i'm not too sure how i'd secure it.  what about clamping options?  the vise doesn't do well at an angle as you are all familar.  i have some C clamps but the base of the saw prevents the clamp from making good contact with both the stock and the saw making everything wrong.  i have a thicker blade on the chop saw to minimize deflection-every little bit helps.
Reply:oh, and thanks for replying so quickly.  your response are helpful.  i'm heading back out to the garage right now to scratch my head (and other places) some more.  i've found that the setup for projects is definately the most excruciating part of fabricating anything.  andy
Reply:The first thing is to make sure you have a good quality cutting disc.  I found at work that Walter are the only viable disc.  The others brands just skip when cutting at an angle and also consume too much power.  I use a sliding tee bevel, bevel gauge or carpenter's bevel to set my angle.  I take the angle off my protractor and transfer it to the bevel gauge.  Lower the disc and set the guage between the stationary disc and the adjustable backstop.  clamp the backstop in position then check the angle again.   When you cut your angle decide which side of the angle you would prefer to err on.  Do you prefer 23 degrees or 21 degrees?  One will be easier to fit with a slight gap than the other.  You are ready to do your cut.  Check the cut and then regularly check the cut as you cut your pieces.  I am saying this after a few days ago seeing a large pile of eight inch heavy wall pipe not cut at 45 degrees as intended.  The person turned off their brain and proceeded to create a large problem.
Reply:Have you tried setting your saw to 22.5 deg as per the previous suggestions then   packing your 4x2 ,2" off the rear fence. You wont get all the way through , then resetting the saw the opposite way pack it again and completing your cut?As always be safe and clamp well
Reply:thanks for all the help.  the cuts came out accurate except for what i'm guessing is blade deflection.  i'm using the widest norton blade i'm able to find and using the least amount of pressure on the handle to get the job done.  i know that there are limitations to the accuracy of a chop saw but i'm a n00b and i want to make sure that i'm touching all the bases.  thanks again!andy
Reply:Originally Posted by racerwadthanks for all the help.  the cuts came out accurate except for what i'm guessing is blade deflection.  i'm using the widest norton blade i'm able to find and using the least amount of pressure on the handle to get the job done.  i know that there are limitations to the accuracy of a chop saw but i'm a n00b and i want to make sure that i'm touching all the bases.  thanks again!andy