Saddle joint help

[Rusty31]

Hey folks I have been given some scraps of 1 1/2" mild steel pipe.
I intend to practice welding them together as i am planning to make a exhaust manifold over the winter.
I have been playing around with my 4" grinder making the shape and the end result was not to shabby. However the time involved was pretty mad and it also doesn't seem very "scientific" if you will.
There must be a better way to do it so results will be consistent
Cheers

 

[eSCHEn]

Two methods - 1) use a proper pattern that a kind soul on the internet has made (eg http://metalgeek.com/static/cope.pcgi) or 2) hold butting pipe against main at the angle you want and trace round it with a sharpie.

I'm sure there's other ways but that's the two I know of

 

[Rusty31]

Yeah as a joiner to trade the second option is what was doing and works ok, just can't see me getting it right all the time.
As for tools is there anything better than the 4" grinder that am using

 

[eSCHEn]

Yeah I use the first method as I plain suck at drawing

Plasma cutter is my tool of choice but a 4" grinder is useable. Not sure how much fun that'll be on such a small diameter though. Smaller discs will yield a tighter radius but it'll be a fun old time.

If the material's not horrid and not too thick a wall then you could do a rough vee with grinder and then fettle the edges with a manual file. Depends on how many you have to do and how much it's paying!

 

[Rusty31]

The 4" is just about to big for the 1 1/2" pipe that I have so could do with something else if it's about.
I am turbocharging an engine for myself and don't plan to make any more however I guess if somebody asks with the right cash then who knows

 

[eSCHEn]

There's tube notchers (cutting and abrasive) but they're not cheap. A very nice one on the for sale section but again, not cheap.

I suppose that it's quite wee pipe so you could try a holesaw in a pillar drill but I've never done it myself so not sure on the quality of job you'd get. Perhaps SWK will add their bit.

 

[Rusty31]

You know I just thought of a hole saw lol, can't see how that wouldn't work so long as the piece was clamped properly.
Mmm might give that a shot

 

[eSCHEn]

Pictures or it didn't happen

 

[Rusty31]

Lol I might be back to my workshop later so take some then, however it's absolutely beautiful outside so it may have to wait till tomorrow

 

[KemppiFrog]

There's tube notchers (cutting and abrasive) but they're not cheap. A very nice one on the for sale section but again, not cheap.

I suppose that it's quite wee pipe so you could try a holesaw in a pillar drill but I've never done it myself so not sure on the quality of job you'd get.

I did try that and found that it is best have a decent support for the hole saw and drill through pipe, rather than just an end. The latter has a habit of taking teeth off the cutter. The jig had a plate that the hole saw worked in to avoid any tendancy to jump or chatter.

 

[eSCHEn]

it's absolutely beautiful outside so it may have to wait till tomorrow

Quite bloody right mate!

 

[Freddy0309]

I tried the pillar drill way and the only way I could get a clean cut was to cut a channel in a bit of ply put the pipe in the channel and clamp the whole lot down other wise it would jump everywhere

 

[Paul.]

With a bit of care its easy in a pillar drill, I do it fairly regularly without problems, another way to make a neat joint in standard size tube is with a pre formed tee, then make butt joints instead, see here,
http://www.mig-welding.co.uk/forum/threads/how-to-make-a-handrail.22424/#post-249100

 

[Freddy0309]

I never thought of doing it up the pip and trimming the end off but thinking about it it makes a lot of sense

 

[Rusty31]

I think the hole saw is a winner for now. I will post up results when they are in
Thanks for the input folks

 

[Rusty31]

Sweet handrail btw, proper job

 

[KemppiFrog]

If you do use a hole saw with the quick change option, don't use the pins. Let the cutter back up against the flange, it is more stable. Paul's nice photo is like that.

 

[colnerov]

Hi, And of course with Paul's method if you tilt the table you can do angled cuts.

Colin

 

[Rusty31]

Eventually got some pics of the pipe, looks ok but am thinking the chances of getting two the same will be small

 

[Rusty31]

This is my first shot at welding pipe, it felt a little different as on my two day course if was only welding in straight lines really.
Don't think it's to bad not to pretty but it's fused well
Cheers