Lay the round bar stock in a Vee and put it under the saw so the saw just
touches the highest part of the rod. As long as the stock is round you'll
have a tangent to the diameter and all you need to do is start slotting,
half in two.
There used to be lots of banana plugs for sale on eBay and hamfest, quicker,
easier, and cheaper than DIY.

--

73
Hank WD5JFR
"Airy R.Bean" wrote in message
...
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.