Awl--
OK... Pretty much have the direction of my assembly strategy, much thanks for the earlier discussion.
So now I bang in my pin, which of course cannot be flush with 1" diameter--or any diameter--tubing.
How do I finish the pinned surface?
- radius the pin first, and align the radiused end so that matches the tubing radius? Then polish?
- set the pin as is in the assembly, slightly protruding, and grind to match the tube surface? Hopefully without hitting the tube too much, as I plan on finishing the tube by spinning it in a lathe with Scotchbrite.
I lean toward (1), but also don't have a lot of confidence in the alignment process, as there is not with which to align. I dread (2), cuz I don't see how to do this without unduly touching the tubing, and then having a finish mismatch there to clean up.
Appreciate as much detail as possible, or alternative suggestions.