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End notching square tube

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  • End notching square tube

    I need to end notch qty (50) 1.5in x 1/8in 6061square tube. The purpose of the notch is so the tube can "hang" on a 10in channel that it is being welded to providing a flush surface on the bottom. The notches do not need to be extremely precise because I have plenty of real estate for welding. Any ideas on a quick and repeatable way to notch these tubes? My first thought was to set up a fence and end stop on a horizontal mill with a 1/2in cutter set at the correct height and then just feed tube after tube through but having a hard time finding a mill we can use.... Click image for larger version

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  • #2
    1 - Set up stops or use a fence on a table saw or vertical band saw.

    2 - Make a jig to mark all the tubes & use a zip wheel on a grinder. Use plenty of wax to keep the wheel from clogging.

    3 - Farm it out to a machine shop.

    4 - Make a guide for plasma torch. Will require more clean up than others.

    5 - Hand held jig saw.
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    • #3
      I vote for the table saw.


      • #4
        If you take a small amount of time to make yourself a mini metal bandsaw you can get the work done and I guarantee you will never be sorry you made this. You will use this tool in the future for all manner of things.
        It is by far the safest way to cut and make small brackets.
        I made mine to fit a Makita portable band saw.
        Last edited by piniongear; 02-18-2016, 06:10 PM.
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        • #5
          Originally posted by ryanjones2150 View Post
          I vote for the table saw.
          I replaced the pullys on my wood cutting table saw with three stage pullys so I can slow it down for metal cutting. the metal cutting blades are kind of expensive but it works great.
          To all who contribute to this board.
          My sincere thanks , Pete.

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          • #6
            I've used my table saw and chop saw to cut aluminum here and there. With the shop saw, the blade tends to load up with aluminum, but if you turn the blade around backwards, it cuts just as well only a bit slower, but it doesn't load up. I doubt I'd try it with thicker aluminum though, just cut slower.