Sorry, but there is a parallel here with cross-drilling
of round stock. You only need to be a few thou out
for it to be very apparent that the hole is off-centre.

In trying to make a 4-leaf banana plug, with the additional
consideration that material is cut away by the saw or grinding wheel, I
expect that a few thou deviation would result in some leaves
of the plug being considerably weaker. In any case, there is
a certain degree of pride in setting out and achieving a
quality result if that result can be obtained with a few
moments of extra planning.

In any case, it is not the steadiness of hand that is the issue,
but the centring of the tool over the product.

"Jack Painter" wrote in message
news:s1wFd.15551$B95.14894@lakeread02...
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.