[mitchntx]

I have a cheap 16" drill press.

I bought a metal hole saw, jigged up a piece of tubing and attmpted to notch the end.

The hole saw would just catch the tubing and bind.
It appears the table isn't stable enough as it will move slightly.

I looked at a tubing notcher. But the one I saw jigs up to a drill press and I can forsee the same issues.

I can plasma cut and grind, but damn that is labor intensive.

How about sanding rolls? rock cylinders?

What is out there?

[bobbylee]

Similar to Trackbird's method, but use a chop saw instead. You can also use cutting wheels in a die grinder. I built my first motorcyle wheelie bar this way and it worked great. It's a little faster than a sawzall. Of course there is still the hand grind to clean up and make the fit right.