If your lathe is big enough to swing it, and your chuck big enough to grip it, you should be able to part it, even if you have to start with a wider dug-out parting groove to let in a toolshank when the stem gets smaller. Then hacksaw the last 10mm or so to avoid a dramatic event on final separation.

Failing that, are there any metal suppliers or other engineers in your area who might chop it with their bandsaw if you mark it up with a Sharpie or suchlike and offer them a fee or a bottle of something?

A local engineering firm would be my suggestion too. Even holding a 7″ billet to make a cut would be difficult in most home workshops.

It might just be possible to make 1″ deep cuts with an angle grinder to reduce the section to ~5″, but even then, hand-sawing would be a demanding task.

On 30 December 2023 at 11:22 Michael Callaghan Said:

My autosaw is too small for this job.

I might be clutching at straws here, but is the saw too small to sever the part or too small for the bar to fit in at all?

In normal use, you would put the ‘large’ end of the bar under the bow of the saw and the offcut in free space. Can you reverse that setup and put the body of the bar in space (suitably supported and secured) and the slim offcut under the saw frame?

If you add an end stop to the setup, you can cut until the saw body touches the part, rotate it and cut some more. Even if it does not get all the way through, it willl minimise hacksawing.

I’ve used my bandsaw to cut larger than it’s capacity, just come down as far as you can before the guides or frame touch something . Then rotate works and cut again. Even if you can’t do it all you significantly reduce the amount that the hack saw has to do.

On 30 December 2023 at 14:44 Michael Callaghan Said:

Thanks chaps. Sorted now.

What is an ‘Autosaw’ mentioned in first post?

2nd question…. how was ‘sorted’ achieved?

Ian P