Scribing a cut line on the sides of the vertical end to match the profile of
the horizontal member is easily accomplished with a scriber laying flat on
the horiz surface, and then conforming to the radiused edges, freehand.

If the scribe was just laid on the horizontal surface and followed around
the radiused edges, the radius lines will increase the diameter of the arcs
(which isn't desired in this example).

Larger gaps are scribed by using a compass or dividers, maintaining a
vertical orientation (in this example) of the two points of the tool.

Maintaining the correct orientation of the points for other applications is
similar to having the adjacent surface contacting the surface that needs to
be cut, which would be the as if the horiz tube was meeting the vert tube
(the way coping is applied in carpentry/woodworking).

--
WB
..........


"Jon Danniken" wrote in message
...
Howdy, I am needing to join (weld) a vertical member of square tubing to a
horizontal member that sits on the floor (all tubing being 2.5" x 3/16").

The problem, as you have likely come across, is that the corner of the
square tubing has a radius, leaving a gap on either end of the piece to be
joined.

How would you tackle this problem?

I can think of using a sharpie and an angle grinder to get it pretty
close. Is this about the best method?

Thanks for any suggestions,

Jon