Posts Latest Activity Photos. Page of 1. Filtered by:. Previous template Next. Tags: None. On fire most of the time. I've done it a few ways. If you have a piece of small tube the same size, and its a straight up 90, you could just grab a grinder, and go to town. Finish with a half round file. Thats the quick and dirty You could also use a JD2 or similar hole saw jig. The angles are much easier to make, and it really isnt that bad when it comes to time.
Use some good tap cutting oil, and it'll work pretty well. Just dont load up the hole saw I've sheared all the teeth off of one in less than 10 seconds, and that was a starrett. They also make one that does a mechanical cut, not sure what size tube you're working with, so that may not be an option.
If you only had 1 or 2 to do, and fitment doesnt need to be dead nuts perfect, the grinder would be the quick and easy way IMO, if you dont want to spend the money on another tool.
Built something using this site? See Examples. If you've benefited from this free service please consider helping us support:. Inch or Metric? Please help promote this free service Tell a Friend! Saved Calculations Select Saved Calculation. Click individual diagrams to remove. Pipe - Tube Notching Templates. Pipe - Tube Miter Templates. Pipe Through Sheeting Templates. Round tubing as well as square tubing can easily be cut by the zip disc, although a hacksaw can also be used if you don't mind the added effort.
In these tutorials, the safety guard has been removed from the grinder so that you can see the action more clearly. It is not advisable to work with the safety guard removed from the angle grinder as a disc fracture could cause injury. Proper face and eye protection such as safety glasses and a high impact face shield are necessary for grinding safely.
When cutting a line around a tube using a zip disc, keep the grinder disc at 90 degrees to the tubing and cut from the top so that you can see the line. If the tubing that you are cutting is long enough so that you can hold it securely with one hand, it is easy to make the cuts while rolling the tube along your workbench, keeping the cutting disc along the top of the tube.
Cut along the line as you roll the tube and you will make a very accurate cut around the circumference of the tube. This method of cutting off a tube can be more accurate than the results form an inexpensive chop saw if you take your time and follow the line. After cutting a steel tube, the edges that remain will be razor sharp, especially on the inside. Be careful. These edges are so sharp that they could easily slice through your work gloves, so they need to be filed after cutting.
It's a good habit to file the edges after every cut, even on the tubing you don't plan to use or may discard. A half round file is perfect for removing the sharp edges on a round steel tub after cutting. Use the round side for the inside of the tubing, running the file at an angle while working around the entire inside circumference. The flat side of the file can be used to take off the outer edged and to remove any high spots around the cut area.
Sometimes there will be a small amount of error where the start of the cut meets the end. This is easily filed down using the flat side of the file. The end of the tubing that has the electrical tape as a guide is cut using the same method, but instead of following the marker line, the cutting disk or hacksaw is run along the edge of the tape on the side you want to cut.
Electrical tape or masking tape will both work as a cutting guide. Using the same method of rolling the tube along your bench, cut with the disc held at 90 degrees to the tubing and stay along the top so that you can easily see where you are cutting.
Keep rolling the tube until the last cut meets up with the start. After cutting, the razor sharp edges are once again filed down on the inside and outside of the tubing using the half round file. A fishmouth cut will typically require a pair of semi circular cuts of equal depth at the end of the tubing. This will allow another round tube to connect at 90 degrees, forming a T shape. Although huge precision is certainly not necessary, the fishmouth cuts do need to be close in depth and adjacent to each other on the end of the tubing.
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