Need some ideas on notching

[handirifle]

I am nearly finished with building my workshop. Once done, one of my first projects I want to do is make a rack to protect the cab of my truck from things like long lumber, etc. Not a full blown roof rack but just one of the tombstone shaped ones, with uprights on each corner to keep stuff from sliding off and visiting other drivers at freeway speeds:ashamed:.

Something like this,
STK Pro Guard Headache Racks & Cab Guards except I haven't made my mind up if I want square or round tubing.

Anyway, to my point, I was wondering if there is a simple (read inexpensive) method of cutting the notches. In the past I have used my radial arm saw with a cut off blade, but i really don't like all the sparks and flying debris, if it can be avoided. I also know there are tubing notchers for joining tubes, but I have never seen one make a notch that is say, a 22.5 deg angle, to make a radiused corner. Is there such an animal for square and /or round tubing?

 

[wroughtn_harv]

Anyway, to my point, I was wondering if there is a simple (read inexpensive) method of cutting the notches. In the past I have used my radial arm saw with a cut off blade, but i really don't like all the sparks and flying debris, if it can be avoided. I also know there are tubing notchers for joining tubes, but I have never seen one make a notch that is say, a 22.5 deg angle, to make a radiused corner. Is there such an animal for square and /or round tubing?

Here's the easiest formula I've found for round. Lay your pipe or tubing on a table. Place a speed or framing square on the table against the edge of the pipe. Measure the distance between the top edge of the pipe straight across to the square.

Two inch pipe (2 3/8" O.D.) is about five eights to three quarters of an inch. Measure in from the end of your pipe that distance. Mark and arc to the ends from the middle. Cut that out. Then turn the pipe over one hundred and eighty degrees and repeat.

Small pipe, one inch and smaller can be done onesy twosy with a grinder. I like using a portaband saw but you can use a sawsall, a torch, plasma, chop saw whatever. When you're done you're going to have the end of the pipe cut into thirds basically. The top third will be cut back for the notch, the middle will be the wings coming out, and the bottom third will be the notch again.

I used this formula for all pipe cuts that I do except for ones less than four inches. The smaller sizes anymore I either use one of my notchers or I freehand it.

This is one instance when I recommend the carpenter's attitude over the weldor's. A carpenter has to cut short and fit because a long cut just ruined the board. Weldors on the other hand are notorious for figuring the crack of dawn is a difficult but not impossible gap to fill.

 

[4shorts]

Good ideas there wroughtn_harv. I had to do some pipe work a few years ago for the Department Of Fisheries and didn't have a notcher so I made one. I included the thread where I posted the project. I've used it for a few years and it's been great. I basically built it out of scrap pieces I had here at the shop and seeing you got a new shop start building a few tools to do your projects with. After all that's what the shop is for

Home made tubing notcher - WeldingWeb - Welding forum for pros and enthusiasts

 

[CharlieR]

Bought one from Harbor Frt Tools for $40 or so.
Made a tubing frame for a stone boat.
Worked OK, just had to shim it a little to get the cuts perfect.
It's adjustable and quick.
Item 42324.
Have fun.

 

[1grnlwn]

Sounds like and looks like from the picture that you want miter joints. < > Where two ends meet to form some angle. This involves straight sawing at a specific angle on both pieces. You need some sort of angle layout tool and something to cut straight. Before I bought a band saw, the sawsall was the tool. Just need a good visible line and some control. Notchers are used for T joints with round tubing and seem to need a lot of fine tuning with the grinder. (buy some extra tubing)

 

[1grnlwn]

Here is our first tubing job. It is still in process.

 

[gauthier]

They sell all kinds of pipe templates and other such tools to help you mark and cut saddles/angles.
What was said by harv works real good for a 90,you can modify it for 45 or different angle branch,,you just got to experiment,till you get what you are wanting.
look at www.ramweldingsupply.com,,they got all kinds of templates,some are better than others,,I've ordered off them many times,,honest company and pretty fast shipping.

 

[handirifle]

OK thanks for the responses. At least now I know, first, what I am looking for, and second, where to look. Helps a lot.

And YES that is what we do with new shops, we find new tools to put in them:thumbsup:.