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As far as tooling goes the Carbide inserts generally have a radiused nose and specific angles for different types of material and as mentioned earlier are generally used on CNC machines that have much tighter tolerances and are more rigid allowing for deeper more controlled cuts with feeds and...

For DOM 1020 you can use a hacksaw, I know its not fun or glorious but a hacksaw with a new blade is a valuable tool.

I believe hydraulic rods are a harden able steel like 4140 and I don't think the cylinders would be cast iron either. Cast iron would be to brittle for that kind of pressure.

Thanks Chris for some reason I didn't think about ordering from COX. Im going to order 10 today.

I see them for 15 dollars on up depending on condition and rarity.

Im looking for some cox .049 cylinders and pistons. I am going to build a 9 cyl radial and need the top ends.

It will also increase your accuracy. One thing to remember tool life and accuracy is greatly increased with rigidity

Its never a good idea to cut between centers. I always get the cut as close to the chuck as I can and part there. If you have your live center it will cause the part to bind. Also sharpen the tooling before every cut.

D2 steel is a semi stainless air hardening tool steel. It is designed to be an abrasive resistant steel.If you are causing enough heat machining it it will harden and be harder than your HSS. You will be better off using carbide and cutting deep and fast than slow and thin.

You have a lot going on there and all of them will contribute to chatter. As mentioned a work work piece is usually ok to not be supported 3x the diameter of the stock your using. So 1" round stock can hang out around 3". This is a good rule for heavier machines and you may find your grizzly...