Tube notcher

I had a few tubes that needed "notching" a while ago, i was using a borrowed notcher but needed my own and didn't fancy buying one or using the lathe or miller. So a couple of pics.

The tubes are 2" by 1" , some rectangular, some oval. They needed notching longways to fit 1" tubing.


First one end of the tube is cut, setting up by eye without the rear round bar in position. The jig is used in a pedastal drill with one table clamp and one G clamp and bolted through the table slots . All tubes are done on one end. Then the round bar stop is fitted and the other end cut giving the right length every time.



It was made from what was knocking about in the shed, with oilite bushes for the shaft (16mm). It is made specifically for that size rectangular tube and also 1" round tube.



This setup, with reasonably quick clamping and guaranteed right dimensions realy speeded the job up.

Just need to sort out some tidy holesaws for the next time.

Nice one wyn

Great job. Did you work out where the stop was going after notching one end or were you ambitious and do that first!

Everytime I start a job and think 'I know. What I really need here is a jig.' I spend the rest of the day making the jig and completely forget about what I was supposed to be doing in the first place. Of course things are always quicker afterwards.

Cheers Jugs.

Archie... I had one already cut with a borrowed notcher, so made up the drill part and fitted the tube up to it then bolted the "stop" on last. Like you say... it would have probably ended up a nightmare any other way

I'm similar.......have a lot of half finished jobs that seemed like a good idea at the time, then something more interesting crops up and they get left.

Ah. That sounds like the sensible way to do it! I've got a load of projects that I've started thinking 'this'll only take a minute'. Half a day later when things are not going quite according to plan (do they ever) and I either give up or bodge it.

Nice! What you doing with the tubing?

They are part of a Trike conversion, i get the tubing supplied ready cut to size and just notch them and along with a few other bits stick them all together using a jig (also supplied).

We do it a similar way, except using a broaching cutter instead of a hole saw.
Nice Jig, How about adding a toggle clamp or two to save using the GClamp?

Hitch .. ..I did buy a long broaching cutter but was stupid and used it in the lathe along with a homemde vice ......first cut......bang the cutter flies across the shed in bits too much play in all the slideways / vice and not rigid enough.

A nice toggle clamp or two would be just the job to make it easier to use

What's realy needed is one of those nice abrasive belt notchers but in the end i don't think the job justifies anything better or more expensive.

I've messed about with lathe type cutters, all created too much vibration.

What I've used in the past is a hole cutter in my pillar drill, I'm less worried about damaging a £100 drill press then I am my Boxford.

But you jig looks good if have lots of repetition to do.

Have you got any of the oval tube spare?

Some hand cut fish mouths, the box section I did on the pillar drill using a hole cutter.

Superb job! Well done!

Is that 1/2" plate for the base? I must admit that I've been tempted to get one, but every time I go to look, they seem, ...well; a bit flimsy! Yours looks nice and strong.

Aero.... I don't have any of the oval tube, the job is for someone else and they give me the tubing ready cut to length.

Knoba.. It is 1/2" plate and like you say the ones you can buy do look flimsy and hard to use for repetitive stuff. Plus the cheapest i have seen is around £70 going on up to £200'ish

Bummer about the tube - I've been after some 2.4 mm wall in short length, about 50 cm. I'd never use a 6 meter length!