How to efficiently mitre tube past 45 degrees

admin

Hey guys. Got a staircase job that consists of a single 3x6 tube spine with the treads mounted centered and on top the spine.   My top cut on the spine (the level cut) is a 55 degree cut.   I only have 5 of them to do but still would like some tips on accurately and efficiently doing so. I did one today by laying out my cut line on one side of the tube and then "trying" to match the angled cut line on the other side.  Then went to town with the angle grinder with a cut off.I have a ellis 1800 that mitres to 50 degrees and i spent over an hr trying to figure out a way to shim the tubing to get my cuts at 55 degrees. Wasnt successful with that. Not at least with 1/4 thick 3x6 tubing thats pretty heavy to move around by one guy.Dynasty 200DX   (2014)Millermatic 211 (2015)Optrel 864   (2014)Smith Medium duty MBA 30510 (Xmas 2014)Tennsmith 16ga 4ft finger brake (2015)Trailblazer 325 EFI and excel

Thermal dynamics Cutmaster 82Miller maxtron 450
Reply:Plasma. That is how I cut mine.  ...across horses.
Reply:I can imagine the saw blade pulling the steel and creating a crooked cut if not properly secured.  Never had the privilege of a large band saw, so o/a, plasma, or circular saw have been my go to tools for large metal.  Plasma is the front runner these days. Also allows me to move the cutting tool to the metal.Last edited by tapwelder; 02-22-2017 at 05:23 PM.
Reply:You could set your saw to 35 degrees. Tack a piece 90 degree to the tube and cut it that way.
Reply:

Originally Posted by M J D

You could set your saw to 35 degrees. Tack a piece 90 degree to the tube and cut it that way.
Reply:Basically the tube would be sticking out the front of the saw, 90 degree to the fence. Subtract your desired angle from 90 and cut. So if you want 60 degree, set the miter angle at 30, then cut. If doing both ends, length would need to be cut first at 90 degree.
Reply:What about a jig set up with a metal cutting circular saw?
Reply:MJD thanks for the tip. Not sure if anything will be in the way (on the bandsaw) enabling me to do that but im going to check into it today. Circular saw could be a good option but i dont have one and not sure if the cut depth would cut all the way through 3 in tube.
Reply:Cut 2 wedges at 30 degrees and clamp them to each side of your tube one point right other point left.  Now set your saw vise at 25 degrees and clamp the tube and wedges in the saw vise.
Reply:

Originally Posted by dmatt

Cut 2 wedges at 30 degrees and clamp them to each side of your tube one point right other point left.  Now set your saw vise at 25 degrees and clamp the tube and wedges in the saw vise.
Reply:

Originally Posted by dmatt

Cut 2 wedges at 30 degrees and clamp them to each side of your tube one point right other point left.  Now set your saw vise at 25 degrees and clamp the tube and wedges in the saw vise.
Reply:dmatt, excellent idea. Thats exactly the kind of tips I was looking for.  I also figured out that I can actually mitre with the ellis 1800 to a max of 55 degrees.   I got it all the way to 54 degrees without any modification (just adjustment of the front blade guide) and with a small grind in a couple spots on the blade guide and on the back fence 55 degrees easy.      Not sure if anyone knows this or not regarding the ellis 1800.Dynasty 200DX   (2014)Millermatic 211 (2015)Optrel 864   (2014)Smith Medium duty MBA 30510 (Xmas 2014)Tennsmith 16ga 4ft finger brake (2015)Trailblazer 325 EFI and excel

Thermal dynamics Cutmaster 82Miller maxtron 450