i've used a hand operated machine that cuts a fishmouth out of one side of a piece of pipe and then you flip the pipe over and cut the other side. all it does is shear it out. but it's quite pricey. i think the one we bought was capable of notching out 2" schedule 40 pipe, and it was up around $1000.

if i wasn't going to do it very often, i'd just play around w/ a torch and a grinder till i found a good depth to cut the fishmouth. then i'd get a piece of cardboard or paper and trace the fishmouth so that all i have to do is put the template on the next piece to be cut and then trace it. then all you have to do is cut it w/ a cutting torch.

I've never used one. I've always used the cutitng torch and a hole saw setup for aluminum handrails.


Gerald Austin

That's what I do. Cut it any way you want, then flatten it a little with a hammer. Hit it from both sides to keep it symetrical. Careful when you do the other end so it stays in line with the first end. If you don't smash it all the way it's stronger.

Bill

Be aware of considerations the Zn may require if you are using galvanized, including fumes and, I am told, cracking

The proper source would likely be one that supplies structural steel "H" sections; "I" beams, round lolly columns, etc. for the construction trade (as opposed to bridges and the like) and they shouldn't be rusty when you buy them unless the price allows for it; they'll be stored in a protected location at the "right" source. Expect quotes on 25' lengths but they may cut them... otherwise you get quotes by the ton.

Home center stores will have the highest price imaginable for these hollow steel sections (HSS) by my experience if you can even find the size you need- often more than three or four times the price.

Good Luck
d