Tried out an Ol' Joint Jigger and it works just peachy for straight cuts. Those angled pieces just kept giving me grief, not to mention that it's not one of life's greatest joys to keep adjusting the darn thing. So I used the Joint Jigger to cut a straight cut, then used the trimmed wheel on the grinder to finish the angle. Worked fast and easy!

Okay, I know everyone has their own way of cutting 4130 tubing, but I swear a simple heavy-duty tubing cutter works great! Hey, they cut conduit with 'em and our tubing walls aren't thicker than those!

Speaking of which, the two bends in the bottom longeron should be done cold. Use a conduit bender and stop when you see the tube bend - that's plenty! And for cryin' out loud, PRACTICE FIRST! Mess up some cheap conduit before going after the good stuff.

When working on the sides, cut two of everything right off the bat.

I've been told on more than one occasion that using a rounded-off grinding wheel to hog away the ends of the tubes is the grunt way to do it. Well, I did it up at Oshkosh one year and it worked fine. Besides, the sparks are really cool! Next time, though, I'd get a bigger hp grinder. This 6-inch Sears thing bogs down too easy - it's only 1/3 hp, so you can't push it hard. But, give it a chance and it will get the job done. Maybe something with a Briggs+Stratton!