Notching Tube with a Chop Saw

[MiniSimp]

Reference thread on PBB
Online Calculator
Input the Outer diameter of the base tube
Input the Inner diameter of the joining tube
Input the angle of the notch

All I have to say is, this works perfect!

[abnormaltoy]

Reference thread on PBB
Online Calculator
Input the Outer diameter of the base tube
Input the Inner diameter of the joining tube
Input the angle of the notch

All I have to say is, this works perfect!

I found this calculator a couple of weeks ago. You can print out the profile, wrap it around the tube, mark it and cut. I've got some scrap aluminum printing plates (.015 or .020?) that I cut the common patterns out of, then Sharpie marked the tube. Open the file in .pdf and print with "No Page Scaling". This one allows you to use different diameters of tubing.
Mark

http://www.metalgeek.com/static/cope.pcgi

[abnormaltoy]

Reference thread on PBB
Online Calculator
Input the Outer diameter of the base tube
Input the Inner diameter of the joining tube
Input the angle of the notch

All I have to say is, this works perfect!

I do like the little notch leftover at the joint, might help to get better welds. What kind of set up did you use on your chop saw to set the angles and keep everything oriented correctly?

[Hyena]

Thats a good idea, i use to notch tube with a torche.

[metalfabpat]

 pretty cool. better than the ol' plasma, grinder and file method. thanks for the link.

[speedemon]

COOL

[Willy Mammoth]

What is wrong with a hole saw?

Use a long 1/4" drill as a guide and follow thru with the hole saw.

[Hyena]

Most people don't have metal hole saws or a drill press.

[Willy Mammoth]

You only need a hand drill and a Ace Hardware hole saw.

Take the short drill that comes with it out and use one of those long drills. Start the hole at the angle you want and follow thru with the hole saw. Just use a slow speed drill and take your time.

You may need to go from both sides if the angle is too great.

Or not, just thought it would be easier than a chop saw.

[Duffil]

What is wrong with a hole saw?

Use a long 1/4" drill as a guide and follow thru with the hole saw.

x2, that's what I've used.  I've had to do it a couple times with a cutoff wheel and a sawzall, and that just blows.

[Hyena]

Actually all you really have to do is set the chop saw to 28 degrees, tighten the tube, cut, flip over the tube, tighten, cut again and you are done.  that is if you are connecting the same size tubes together. It will close enough, it isn't rocket science. 

[MiniSimp]

I thought it was 18.5 degrees?

[DTB]

close enough, it isn't rocket science. 

[Hyena]

i was wrong, it is 28 degrees from 1.75-1.75 tube.

[Ramrod]

you guys are making this way to technical, just cut the tube at a 90* and crank the wirespeed all the way up and fill that sucker in

[Hyena]

you guys are making this way to technical, just cut the tube at a 90* and crank the wirespeed all the way up and fill that sucker in

Not like i haven't done that before. 

[Ramrod]

works wonders on big holes in sheetmetal

[locktup]

Ive been using a chop saw for years. I can usually get it on the first cut. I like it much better than the hole saw tube notcher I have that collects dust. I also have a manual notcher, that I use more that anything now. But that will only notch to about 38 degrees, so I still have to use the chop saw for one side for angle greater than 38 degrees.

I think I'm going to sell the hole saw tube notcher. I will post a picture of it in the for sale section later.

[Tice]

I've been doing it for years too. I like that it leaves a bevele(sp) so you don't have to take a grinder to it.

[mad maud]

nice this will be most useful when building my roll bars etc

[notajeep]

I just bought this and it works great and only cost me about $40.
http://www.harborfreight.com/cpi/ctaf/displayitem.taf?Itemnumber=35782








EDIT: the one that I have was the same price but a different model # and goes to 60 deg.

[Willy Mammoth]

What is the number on that one? I want to see if the local HF has one in stock.

[rednk1980]

I use a band saw works awsome cut all the notches on my bed and bumper with it.

[notajeep]

What is the number on that one? I want to see if the local HF has one in stock.

I'll get it for you later today. But it was right there with the other one. They were both on sale, but the box looked a little different. I checked them out and the only diffenence was that one was 45 and the other was 60 deg.
Dan

[RRMike]

For straight notches this is what I do.  I don't even bother tightening it down I just whack one off flip it 180 and cut the other side.  For angles though I do use my pro-tools hole saw type notcher.  I don't wanna try to figure the math for some of the funky angles I've had building my cage

[Skinny_Pedal]

i prefer my tube notcher