thanks, ive actually seen the chop saw notching thread....i would probably do it with the paper towel roll template...but i just didn't want it to come out all butchered. I also thought the square would be pretty unique, but i think ill opt for the round. Man it would be nice if we could all have a machine shop worth of benders and notchers and stuff in our garages, huh? By the way, would a millermatic mig with gas do the trick on DOM? Not sure if it has special welding properties or anything like chromoly does.