(81 days until the 2012 WHPSC)
Our Harbor Freight tube notcher had a tough time with 2-inch by .049 tubing
Despite just about breaking my wrist when the holesaw grabbed at the very end of the cut, I managed to get a decent notch.
After a little deburring, here's how the pinch tube will fit...
Speaking of pinch tube, rather than mill completely through the pinch tube, I left some thin spokes that I can zip saw after welding...
Jigged up, and ready to weld (notice that large block of steel in the lower left that I'm using to support the step blocks).
After welding most of the pinch clamp, I loosened the step clamp fixturing. The large steel block fell off the table, barely missing my right foot! I repositioned the subframe pinch clamp to finish welding it, but the TIG welder wouldn't light. Upon closer inspection, I found out why...
That could have been my foot!!! The look on Smokey's face says it all...