King Kutter has illustrated instructions in their Adobe acrobat manual for their rotary cutters. Find it at <A target="_blank" HREF=http://www.kingkutter.com/>http://www.kingkutter.com/</A>
The last one that I had done, I took to a machine shop. They put it on a lathe, cut the yoke off one end, cut the shaft, welded the yoke back on and balanced it. $20. Been a few years ago though.
I agree with Von,use a sawzall, unless you have access to either a chop saw or a metal cutting band saw (floor model, not portable) as it is easier to get a straight flush cut. You can even use a hacksaw if you don't have access to power tools, but its a lot more work.
EdKing,
I did use a hack saw after I discovered that my son had used all the blades for the Makita recip saw. Did OK, would rather have done it with power though /w3tcompact/icons/smile.gif .
Like the others (except for the power tool challenged), I used a Sawzall. One trick I learned from an old timer was to use a dowel or skinny piece of scrap wood as a story stick to get the length right the first time.
Yeah, those recip saws are nice. I have a Porter Cable tiger saw. What a work horse. I recomended the other saws as I some times have trouble drifting when I am cutting with the recip. My wife even bought me a cordless Black & Decker recip for Christmas, its nice for small jobs where there is no power, but doesn't hold a candle to the Porter Cable.