[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?

[slowTA]

I also found a cone shaped grinding stone in a box of my Dad's stuff. I may attempt to chuck it up somehow, crank up the speed and see what happens after using either my chop or sawzall ...

Some of those old stone things are known for flying apart every now and then so I would keep the speed pretty low.

I'm captain of my school's SAE mini baja team and we're looking into buying a cutter that looks like a soda can and has teeth all the way around the perimeter. We saw a guy using one of them a while back but our budget was pretty crappy last year. I can't remember the name of it right now but you can chuck it in a mill and slowly move the tubing in as it chews away the correct shape. I'll see if I can get a pocture somewhere.

But last year we used a tubing notcher and some hole saws from Home Depot, the white bi-metal type and they did an OK job at best. We used 2 of them to build the whole car. Don't forget to use some type of cutting fluid to keep from binding.