Sean in CT wrote:
i use hole saws in my bridgeport. I buy the hole saws with the built in arbor, then machine the arbor (in the lathe) to fit in a collet. Usually only have to take a little off and it really squares it up nicely. I don't use the drill bit. Then i use an angle finder and clamp it in a vise. Kinda like a giant notcher. Just feed slowly to avoid tearing the teeth off.
This is what I've done so far. I have a set of tall jaws and various V blocks. Combined with a digital angle finder, it's worked quite well. But I feel like it's a lot of abuse on the quill. It's much cheaper/easier to replace a whole tube notcher than repair the head on my Bridgeport. Seems to be a lot smoother when I've used end mills instead of a hole saw. But a HSS 1.5" end mill dosnt last long cutting chromoly tube. And a Carbide cutter can be the cost of the tube notcher alone.
Ok... you convinced me. JD2 Notcher it is. Lol...