Cutting 45's on square tube

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What's the best way to cut 45's on 1" and smaller square tube?  I have tried with a milwaukee portaband by trying to cut it horizontally and ease it onto the mark I have also held the saw vertically and marked the side with a vertical line then cutting the angle I also have a plasma but that would be messy with my current skills. Is the chop saw the way to go? I know a horizontal band saw would be best but just don't have the room for it. Managed to weld a 10x17 rectangle together out of 3/4" 16g tube but took alot of filling in and ended up square. Any help would be appreciated.
Reply:Yes, a chop saw is exactly what you need. And some hearing protection.Those things are easily adjustable, but one thing; NEVER trust the markings on the fence, those things are (almost) never right. Be sure to use a square to make sure its all good.[Account Abandoned 8/8/16 Please Do Not Attempt Contact Or Expect A Reply]. See you on YouTube! -ChuckE2009
Reply:When you pick out a chop saw, be sure to buy a good one.  My cheapo Harbor Freight saw has enough power to cut through just about anything as long as you are patient, but it doesn't cut straight vertically so joint fitup can be rather poor on a mitred corner which will make welding it up a challenge.  If I had to do it over again, I probably would have continued cutting freehand with the grinder and saved my money for a better saw.
Reply:+1 on that.I've got a Makita chop saw which I love, and would buy again in a heartbeat. I highly recommend those, they're pretty popular and you see them in the backgrounds of many pictures posted on this site.[Account Abandoned 8/8/16 Please Do Not Attempt Contact Or Expect A Reply]. See you on YouTube! -ChuckE2009
Reply:Miters are certainly possible with a Port-a-band. For this, I'd run as fine a tooth blade as you can. I usually mark out the 45 with a machinists square and a fine sharpie and then make the cut top to bottom. I set up so the saw guide is on the inside of the miter and hold the work in a vise. In some cases I've found tacking a small chunk of angle set sideways so the saw guide has a 90 deg surface helps, especially if I have to free hand the cut without a vise.I also know several guys who have put the time into building miter boxes to hold a Port-a-band.Never had a lot of luck getting decent miters with an abrasive saw. Usually they are close, but not a true 45 deg unless I spend a lot of trial and error to account for wheel deflection. I'd rather go with a carbide multi purpose saw instead, or my horizontal bandsaw. For one or two cuts I usually use the port-a-band. If I need more, I use the horizontal bandsaw..No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:Actually a dry cut carbide does a excellent job on tubing, my first choice would be a carbide wet saw, then a bandsaw.An abrasive saw leaves a nasty edge, it will work but definately not the best tool for cutting miters. I am building miter cornered tool boxes for my truck, this is an older pic and I am a lot further along but is the newest pic I have on the computer:
Reply:Chop saw with carbide tooth blade. Piece of cake.JasonLincoln Idealarc 250 stick/tigThermal Dynamics Cutmaster 52Miller Bobcat 250Torchmate CNC tableThermal Arc Hefty 2Ironworkers Local 720
Reply:Thanks guys appreciate the help might try to make a small guide with some angle for the portable tomorrow
Reply:One way to avoid all the grief is to cut everything square then once tacked together make up square plugs to fit in the open ends.  We do that all the time on large structural square tubing.  The square pieces can be almost any thickness as long as they fit inside the tube end.  It is much easier when welding because you do not have any walls butting together without something on one side at least to absorb the heat.  You are less likely to blow through on light gage.
Reply:As a proud owner of a Milwaukee porta-band I can honestly say free hand 45's are tough. Doable but tough. The Milwaukee is kinda heavy to hold back and guide through slowly. The backend wants to slide along the piece once it bites in and you need those dual action-independent lizard eyes to watch the cut on the back, front and top planes all at the same time. I've done it but if I knew i was always going to be doing angled cuts I'd some something else for that purpose."The things that will destroy America are prosperity at any price, peace at any price, safety first instead of duty first, the love of soft living and the get rich quick theory of life." -Theodore Roosevelt
Reply:I am not sure how long the pieces are you are cutting, but one of these version of Swag Off-Road's table may make it much easier.  [ame]http://www.youtube.com/watch?v=3_BV7_OEttI&feature=uploademail[/ame][ame]http://www.youtube.com/watch?v=GH6jBOXWjIo&feature=endscreen&NR=1[/ame]TxDoc's Photos Lincoln SP175 PlusLincoln Power Mig 256Lincoln 250 LX Spool Gun Lincoln Precision Tig 225 Hypertherm 600 KMG 2x72 Belt GrinderBaldor 812RE Grinder
Reply:Dry cut carbide tipped chop saw is by far the easiest way to do this. We have three of the Makita 12" carbide saws in our shop. They are loud but by far the best way to cut small tubing in my opinion. I cut hundreds of miters on a daily basis, and I could not do it without this saw."If you live in Sacramento you have seen my work."
Reply:chop saw blades tend to flex slightlyyou will notice this if you cut two pieces and try to match them up for a 90and turn over one of them just learn how your saw cuts and compensate for itMM 180
Reply:I use my carbide blade chop saw. I set it up using a the head for my combination square setting it against the vice and blade. They come out very nice.
Reply:Ok thanks anyone heard about the carbide saws at Lowes? I think they are the rage evolution I know it's a European company but are they made in china? The circle saw looks pretty cool but haven't found many reviews
Reply:There have been any number of reviews on those saws here in the past. Search "Rage" and "Evolution" and you'll get a bunch of threads to go thru..No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:Do at least 50 miter cuts a week with the Evo. You have to know your equipment and work with it. I've been working my Evo for past 7 months with a bent arm that throws it off 1/8". it's just finding the time to send it in for repair and bring out the ole abrasive, ugggg
Reply:Dewalt and Jancy are a couple of other brand names of miter 14 inch saws.
Reply:Is it possible to put a carbide tipped blade on a miter saw intended for wood but use it for cutting steel?Ranger 305gMillermatic 140 AutosetDewalt Chopsaw2 grindersMy Fists
Reply:Originally Posted by bp626indamixIs it possible to put a carbide tipped blade on a miter saw intended for wood but use it for cutting steel?