Railing job

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This is what i have been doing at work for the last few weeks. Normally we make these work platforms and they have 2x2 sq tube posts and welded cross bars from 1 1/2" tubing. This batch of platforms has 1 5/8" formed railing with cross rails that need coped. So i have like 390 rail sections to fit and tack together for the welders. Plus they have pockets that the rails sit in and need to all be removable. I have found the quickest way to cope the 1 5/8" tube is with a grinder and 36 grit sanding disc. Like 30 seconds per end. Just measure between the uprights and add 1/2". Then scribe a line 1/4" from the tube end and grind to the line while feathering to the center of the tube then roll the tube 180 degrees and do the other side. Piece of cake...Bob Attached ImagesBob WrightSalem, Ohio  Birthplace of the Silver & Deming Drillhttp://groups.yahoo.com/group/southbend10k/http://groups.yahoo.com/group/sawking/1999 Miller MM185 w/ Miller 185 Spoolmate spoolgun
Reply:Pretty much the same thing I do on simple copes like that, except I use a 6 inch Metabo with a slicer wheel. Its amazing how some guys will screw around trying to fit them. For angle copes [ such as stairway railing ] I use a short piece, fit the angle then make a pattern with a piece of larger tube or light cardboard. Looks good.Miller xmt304,  Miller S22 p12, Miier Maxstar SD, Miller 252 w 30A, Miller super32p12, Lincoln Ranger 9, Thermal Arc 181I with spoolgun, Hypertherm 10000 ,Smith torches. Esab 161lts miniarc.
Reply:Really, nice looking job.  How do you get the sides symmetrical?  I use a horizontal band saw, surely slower than a grinder, but works for me.
Reply:Bob, looks nice. At the number your doing would a notcher like the Low Buck notcher speed things up?http://www.lowbucktools.com/notcher.html
Reply:Originally Posted by forhireBob, looks nice. At the number your doing would a notcher like the Low Buck notcher speed things up?http://www.lowbucktools.com/notcher.html
Reply:Lowbuck is a nice tool for field use or even a roll cage.  However,  I would get a tool that was powered by something other than a human.  Manually that much tubing could cause physical injury.  You can get a notcher to go into your press for about the same price as the lowbuck.Lowbuck notcher is a nice tool.  From experience, not a tool i would choose for high volume notching.  What did you use to make your bends?  what tubing size?