What is the best way to prep square tube for welding to round?

[76mx]

Here is the finished product.

[76mx]

These are scraps of .120 wall DOM that were cut on the Harbor Freight notcher. This overly thick stock was for a-arms and it cut just fine.

[kmb58]

I appreciate all of the feedback guys!

I'll try the $40 harbor freight unit. I don't have too many cuts to make, plus if it needs to be a little more substantial, I can just beef it up. Looking forward to experimenting with this thing.

[01Lambiero]

Eastwood's tubing notcher:

http://search.eastwood.com/search?w=tubing%20notcher


01

[diablodoc]

Good bi-metal hole saws work very well and will stand up to many uses if you make sure to use a lot of oil and go slowly.  I'm not sure about the hole saws from Harbor Freight, but I always use the Lenox brand from Lowe's.  I've used these to cut numerous holes in up to 3/8" steel plate and I have yet to replace one.  Lots of oil is the key.  Good luck.

[jdinner]

Have a look at this. May come in handy after you get the tools.
http://metalgeek.com/static/cope.pcgi

[kmb58]

I was just eyeballing the notcher today. I was most curious about the cutting tools. those look "toothed"  for wood..  I actually picked up an 18 piece kit for 9.99 with today's coupon..

Harbor Freight sells a tool to help you do it and the Bi-metal hole saws.

http://www.harborfreight.com/pipe-tubing-notcher-42324.html

http://www.harborfreight.com/34-in-2-12-in-bi-metal-hole-saw-assorted-set-14-pc-68990.html

[autopro]

Harbor Freight sells a tool to help you do it and the Bi-metal hole saws.

http://www.harborfreight.com/pipe-tubing-notcher-42324.html

http://www.harborfreight.com/34-in-2-12-in-bi-metal-hole-saw-assorted-set-14-pc-68990.html

[kmb58]

I searched the net- cant seem to find anything helpful. Surely a hole saw is not going to last too long cutting steel. What is the best way to prep square/rectangle for fitting to round?