This is a trick that I have been using for more than 30 years and thought it would be a nice X Mass gift to all my fellow Gear Heads. You don't need any special tools to make a perfect fit to weld 2 pieces of round tubing. All it takes is 2 straight cuts at about a 45 degree angle leaving a little less than 1/3 of the center square on the end. I know it sounds strange but it does work. here is a picture to show what I an trying to explain. I made the cuts with my band saw.
Good stuff! I teach my students that method, and it's pretty hard for some of them to wrap their heads around how a straight cut gives you a curved shape... I've gotten to the point that I just make those cuts on the long tube instead of cutting to length and notching separately. Saves on scrap, too. Especially on 4130.
It also works for tubes that are not 90 degrees to each other. Once you understand it you can experiment with the angels to make it fit. I used a disc sander for this one, took less than 1 min
Wow... so I just got a personal message from some guy that told me that this can not work and that I used special tools to do it! I told him that it is not a joke and to try it for himself. It is all true! It just makes me wonder how many people think this is a big joke? If you do you might want to try it!!!
Just proves sometimes the right answer is the simple one or the simple answer is the right one. Either way. Brilliant!!!
Yes it does in fact work awsome. I have a tube notcher and about half the time I use it. Sometimes its just easier to cut it and clean it out.
Yep .I have one of the tools that use the hole saw, most of the time it is quicker and less mess to do just like you have. Thanks
Been using that method for over 40 years. I've got a mill set up to do notching as I built roll cages for Howe Racing enterprises for over 16 years but the oddball angle notch can be made with an air tight fit using this method after some practice. Almost everyone with no experience will tell you it won't work by just describing it and the look on their faces is one of wonder when you show them. Anywhere two round surfaces intersect they do so in a straight line, all you have to do is orientate your line of sight along the intersecting line and like magic a straight line appears. Frank
I had to stare at the pics for a few minutes, and suddenly it was all very clear. I couldn't figure out from the text if you were cutting across the pipe, or down into the end of it. As I'm staring at the pics, scratching my head, my eight-year-old comes in,looks for about 1/2 a second and says, "I get it!" Damn kids.
I am glad to see that some "old pro's" jumped in to say that they have been doing this for years. Thanks guys.
I saw Don Long do that 40 years ago. Amazingly simple way to fit tubing. The 90 degree joint is easy. The angle joints take some experience to visualize how to angle the saw cuts.
Gonna have to try this. I'm going to build a 'lakester' header for my banger. Any suggestions or hints for the small pipes going into the cone?
Wow are you talking about the Don Long that built top fuel cars? The reason I ask is that we have a 1969 Don Long car that we saved and take to a lot of shows so people can hear it roar.
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