16. After cutting the 11/4" pipe for the frame to length allowing for a 3/8" saddle depth, I used this simple shop-made tool to cut a 90° saddle. Set the radius cutting attachment to the desired radius. Subtract the saddle depth from the radius and set the end of the tube that distance from the center punch on the tool. Make the cut by starting in at the top center cutting out to one side then the other.
17. Rotate 180° (or half turn) and repeat.
18. After cutting one end, turn to the other end and set verticle with a square and clamp in place.
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19. With all of the frame tubes finished, cut the gussets. I cut radius for appearance on all of these.
20. Clamp the frame tube and gussets for welding. The piece of steel with a hole protruding to the front is simply a shim used to hold the gusset on center of the frame tubes.
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