Gord, try shimming the square tubing in the vise so the cut begins on the corner of the tube instead of the middle of the flat spot. You'll get a much quicker penetration into the open part of the tube. A 1" thick spacer against the non-movable part of the vise should be just about right.
I've found that a variable speed Sawzall with a relatively fine-toothed blade makes for quicker cutting on square tubing than abrasive wheel chop saw. Use a square and a sharpie to draw a guide line around the tube, start at a corner, and turn it in the vise if necessary to get an accurate cut on all sides. Jerry
"It is better to be silent and be thought a fool than to speak and eliminate all doubt!" - Abraham Lincoln Cringe and wail in fear, Eloi- - - - -we Morlocks are on the hunt! There is nothing noble in being superior to your fellow man; true nobility is being superior to your former self. - Ernest Hemingway Love your enemies and drive 'em nuts!
