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[erj]

We use a chop saw and I agree it's not great but we also use quickfab elbows where we don't want to be worried about the round edge of the tube. the elbow matches the tube and comes with a bevel so it eliminates grinding also....

[erj]

I would love to see some pics of things you make with the elbows.
Thanks...

[erj]

Or you can use a ready made elbow like quickfab elbows. here is a picture of a display stand we made with them and powdercoated....