I have the same boat, same mast, and going to do the same job.
Many good suggestions listed above, various tools listed will all work fine when used properly... except the oscillating tool, I don't think that's a good choice as its too squirrely.
I don't think anyone really said much about 'setting up' your cut. Put the mast on a set of sawhorses or something similar, at least three if not four. With just two it will sag in the middle. One support has to be relatively close to the cut for support. Be as level as possible. It was mentioned above to use tape; yes, yes, YES! Tape it up with blue or plain masking tape and mark you cut all the way around with a sharpie, careful it is square and if your line looks funny then try it again with fresh tape. Secure the mast to the sawhorses with quick clamps or even rope to keep it from moving or bouncing.
The OP pointed out using low tech so there is no need to buy any expensive tools, just a hack saw and a fresh blade, all you really need is a steady hand and follow your line. Cut off wheels on a 4 inch grinder is the next step up but you have to be extremely careful and hopefully have some experience with this tool. that beast can get out of hand (and out of square) quickly if you are not paying attention. A recip saw will work too, but I find that to be less accurate than a hacksaw in this application and likely to get out of hand faster than the cutoff wheel. No matter what you do the cut with use a fine file to clean up after.
I have a Dewalt Chop Saw specifically designed to cut metal (DW 872, carbide blade, NOT the abrasive fiber disc, those deflect like crazy). I'll probably use that saw to make my cut, but at the end of the day it will take way longer to set up that cut, it might just be more efficient to use a hack saw. Anyway, that's a $500 saw so its no something everyone has in their garage. I love it, it can handle just about anything I throw at it. I've cut 2 x 2 x 1/8" angle iron as well as 5/8 Stainless solid rod, straight butter baby!
Many good suggestions listed above, various tools listed will all work fine when used properly... except the oscillating tool, I don't think that's a good choice as its too squirrely.
I don't think anyone really said much about 'setting up' your cut. Put the mast on a set of sawhorses or something similar, at least three if not four. With just two it will sag in the middle. One support has to be relatively close to the cut for support. Be as level as possible. It was mentioned above to use tape; yes, yes, YES! Tape it up with blue or plain masking tape and mark you cut all the way around with a sharpie, careful it is square and if your line looks funny then try it again with fresh tape. Secure the mast to the sawhorses with quick clamps or even rope to keep it from moving or bouncing.
The OP pointed out using low tech so there is no need to buy any expensive tools, just a hack saw and a fresh blade, all you really need is a steady hand and follow your line. Cut off wheels on a 4 inch grinder is the next step up but you have to be extremely careful and hopefully have some experience with this tool. that beast can get out of hand (and out of square) quickly if you are not paying attention. A recip saw will work too, but I find that to be less accurate than a hacksaw in this application and likely to get out of hand faster than the cutoff wheel. No matter what you do the cut with use a fine file to clean up after.
I have a Dewalt Chop Saw specifically designed to cut metal (DW 872, carbide blade, NOT the abrasive fiber disc, those deflect like crazy). I'll probably use that saw to make my cut, but at the end of the day it will take way longer to set up that cut, it might just be more efficient to use a hack saw. Anyway, that's a $500 saw so its no something everyone has in their garage. I love it, it can handle just about anything I throw at it. I've cut 2 x 2 x 1/8" angle iron as well as 5/8 Stainless solid rod, straight butter baby!
Last edited:
