I tryed a combination bench grinder and dremel tool tonight. The two work very well together. First I mark the angle of the joint and the center line. Then grind most of the material off. This naturally starts to round a groove in the tubing.
Then i used the dremel with a 5/8" bit which wants to center in the groove, as I round the groove to fit the contour of the longerons which is mostly 5/8". A little test fitting results in a fairly tight joint with the appropriate angles. Much like sanding wood joints, it takes a little practice. I feel like I have a good system in place now.
90 degree right angles proved to be slightly more challenging for me, which I was not expecting.
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