How to cut end caps for pipe?

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The welding I usually do is for exercise equipment, and I just finished a dip stand with the uprights made out of schedule 40 pipe and they are open on the ends.  The equipment stays out in my driveway so I want to close up the top ends.  What is the best way to get the end pieces/circles cut if I don't have a A/O or plasma outfit? I have a small bench-top drill press, angle grinders, reciprocating saw, bench grinder and the cheapie 110v HF flux-core welder.The caps don't need to be thick so I was thinking of using a hole saw on some thin sheet metal.  Does anyone have any other ideas?  I will post pictures of the stuff I have made in the projects section when I get a digital camera.ThanksBart
Reply:That would have been my first suggestion is a hole saw. Then simply tack a nail or rod to them and hold in place as you weld around.Patriot Performance AutoLincoln Power Mig 255CLincoln AC-225 StickVictor Journeyman O/AQuincy QT-5 Compressor
Reply:Sch 40 pipe? How about a coupla four  bucks apiece for weld on caps? Like this: http://www.mcmaster.com/library/20060314/45005K236L.GIF from McMaster (socket weld) The butt weld caps are several times the price. To do it yourself, a hole saw or annular cutter. Cut a bit smaller than the OD of the pipe so you have somewhere to lay a nice fillet. Overfill slightly, then dress to a smooth radius, if you want it pretty.
Reply:A hole saw will work for cutting em.But there are all kinds of em for sale, cheap.I usually buy from Wagner/JG Braun- they supply a lot of the downstream guys like King- but there are plenty of choices of suppliers of precut circles, pound on caps, or even fancy fence finials.http://www.jgbraun.com/http://www.juliusblum.com/http://www.classicirononline.com/http://www.kingmetals.com/http://www.jansensupply.com/
Reply:Watch out for "blowholes" when sealing tubing......zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:All of the vendors above will have what you want, order it and wait.  However, if you want it now! Take a sample of the pipe you want to cap to your local auto auto parts store, ask for  the required size "Freeze Plug", ( 1 5/8" for shed. 40 - 1 1/4" pipe, sometime a bit smaller to weld and grind) There are usually two types, one is dished with no sides and the other style has a 3/8" +- shoulder. They are a bit thinner than the pipe but I have used these for years. Also, they look more fished than the flat hole saw type, and you don't need to fill the drill hole.Just my  opinion, not from a book, just from the road.Howes Welding Inc.www.howesweldinginc.com
Reply:Thanks for the ideas, I think I will try to cut some out just to work on my limited fabricating skills.  If this is not working I will do the freeze plug thing.  And I am not worried about blowholes in that the bottom is not completely sealed.Bart
Reply:Many of the LWS carry weld on pipe caps if you are like most of us and want it NOW.DennisThermal Arc 185-TSWMillermatic Challenger 172VictorO/AAtlas Craftsman 12 by 24 LatheEsab PCM-875Wholesalem Tool Mill-Drill