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I don't think I've ever set anything on fire from grinding, but I've definitely caught my shirt and pant on fire welding. This is why you wear natural materials. Cotton will catch on fire, but can be put out really easily also, and generally won't hurt you. Synthetic materials on the other hand...

This is the way. Even if you don't have a chop saw, you could use the same technique with an angle grinder or other metal cutting tool. I've built bumpers and cages this way with an angle grinder. Hole saw won't work unless you have a rigid way to hold it (like a tube notcher, mill, lathe...