I'd put the bar in a vise and do it by hand, so what if you waste an inch of
stock at a time if you aren't happy with it? This isn't rocket-science
making a plug Airy, just have at it for Pete's sake. I could hold a tiny
Dremel-tool or a big 1/2" drive side-grinder steady enough to do what you're
asking with one eye closed.

"Airy R.Bean" wrote in message
...
How would you set it up to be exactly cutting a diameter?

"Jack Painter" wrote in message
news:kWvFd.15549$B95.11334@lakeread02...
"Airy R.Bean" wrote
Is there a "kink" for setting up a slitting saw to saw through
round bar stock along the axis, so that the slot is exactly
across a diameter? (I presume this to be a similar problem to
setting up accurately for cross-drilling)
This is actually a Ham Radio application; I wish to make
up some very large banana-type plugs from the 1/4" round
bar stock that I have in small quantities. For this, I will need
to saw two diameters in a cross shape, and then splay
out the leaves slightly to make a springy and rubbing contact.
Hi Airy, couldn't you just use a grinding/cutting wheel to do this job?
Doesn't sound like you need any fancy jig to cut a slot or two into
round
stock.