HOW TO: Tube Notching

astroracer · #1 (**permalink**) 06-28-2006, 02:05 PM

Hey guys, I don't know how many of you do your own cage or chassis work but this how I set up my jigs for notching tubing.
I set all of this up on one of my jig tables but it will work on any bench or table top you have handy.
These pics show my Harbour Freight tubing notcher clamped to a 90* angle plate. This is simple to set up and doesn't require a lot of thought...

From the backside...

Cutting the first notch is the easy part. No orientation, no length to worry about. Just clamp the tube in the notcher and do the deed.
Cutting the second notch is where some planning needs to be done. Getting the LENGTH and the notch ORIENTATION correct is critical to having a usable part versus something to practice welding on...
To do the second notch I bolted a short piece of the mating tubing to another angle plate and use this to nest the "first" notch into while cutting the second notch.

This way I can establish the correct length AND notch orientation in one easy step... Set the tubing length between the outside diameter of the tubing and holesaw, in this case 23 inches, square up the jigs, clamp it all down and cut the second notch. Once it's set up any additional tubes will be identical to the first so measure twice and cut once...

Cutting the second notch...

Thanks for looking
Mark

DanO · #2 (**permalink**) 06-28-2006, 05:06 PM

yeah.. wish they would have one of those that goes above 60 degree angles... Heck most do less than 50.

Bishopjay · #3 (**permalink**) 06-28-2006, 06:45 PM

nie to know

astroracer · #4 (**permalink**) 07-06-2006, 10:03 AM

Thanks guys,
I got a little bit done over the weekend. Didn't have a lot of shop time but I did take advantage when I could...
Got the notcher fired up and ran the lower crossmembers through it. It took about half an hour to get the jigs set up and another half hour to run the tubing through.

I use Castrol wax lubricant on the hole saw.
[img]
http://209.125.219.235/~forum/attachment.php?attachmentid=253&d=1152185919[/img]
This stuff works really well and doesn't make the mess that WD-40 or cutting fluid does. It also cleans up easily. I can do one notch in about 30 seconds running the notcher with my 1/2" Milwaukee drill.
[img]
http://209.125.219.235/~forum/attachment.php?attachmentid=252&d=1152185922[/img]
This set up makes for a clean cut and, with a little clean up with the angle grinder, I have some quality notches that fit well for Tig welding.
[img]
http://209.125.219.235/~forum/attachment.php?attachmentid=254&d=1152185919[/img]
[img]
http://209.125.219.235/~forum/attachment.php?attachmentid=255&d=1152185919[/img]
Thanks for looking.
Mark

greasemonkey · #5 (**permalink**) 07-06-2006, 03:50 PM

Quote:

Originally Posted by astroracer

This set up makes for a clean cut and, with a little clean up with the angle grinder, I have some quality notches that fit well for Tig welding.

that's good to hear. how much did that run you at harbor freight? is it pretty decent quality for coming from there?

astroracer · #6 (**permalink**) 07-06-2006, 04:27 PM

Quote:

Originally Posted by greasemonkey

Quote:

Originally Posted by astroracer

This set up makes for a clean cut and, with a little clean up with the angle grinder, I have some quality notches that fit well for Tig welding.

that's good to hear. how much did that run you at harbor freight? is it pretty decent quality for coming from there?

It works just fine... I got this one off eBay for $28 bucks... Shipped...:beer:
I keep the spindle lubed with WD-40 and have had no problems notching 2" OD x .125 wall tubing with it...
What I was doing the other day was 2" x .095 wall and the notcher went through it smooth and fast... I use good holesaws though... Look here...
http://www.use-enco.com/CGI/INSRIT?P...PMPXNO=3008824
Mark

greasemonkey · #7 (**permalink**) 07-06-2006, 06:41 PM

i hate cheap crappy hole-saws; hate them. $28 is pretty dang cheap! I'm going to need to get one as I'll be building a cage for the '54 F100 I'm working on and eventually for my nova. good to hear they're clean enough to TIG

astroracer · #8 (**permalink**) 07-10-2006, 10:41 AM

I actually made some headway on the project this past weekend. Not a lot but at least I am moving forward again.
I got busy real early Saturday morning. I was up at 5:45, made a pot of coffee and was out in the shop at 6:15 am.
I wanted to use a die grinder and cutoff wheel to cut the (welds) on the old frame so I had to get my compressor running on automatic again.
It is a used compressor (7 1/2 horse, 2 stage, 80 gal tank) and the pressure switch had been monkeyed with. I pulled it off and un-monkeyed it. Straightened the contacts and cleaned them up. I put it back together, fired it up and she now starts at 90cfm and stops at 150... Good enough for me! I then made this pile of scrap in an hour or so...

Most of the bubblegum welds broke easily with a hammer after I cut one side apart.
I think I will make a heavy duty cart out of the lower ladder frame. A plywood floor and some wheels/tires should make it usable.
Thanks for looking.
Mark

astroracer · #9 (**permalink**) 07-10-2006, 10:42 AM

I didn't get out to the shop as early Sunday as I did Saturday but I still got a lot done. Yesterday afternoon I started cleaning up all of the pieces I will re-use from the old frame and I finished those up today. Grinding off the nasty old welds probably took as long as it would have to make new pieces but I couldn't see not reusing the old ones. I would have spent the time either way so why waste the material...
I did a quick mock-up of the new lower rails and crossmembers to see what the fit-up looks like. The notches came out great and I have some really nice tight fitting joints for welding.

A couple more...

I still have to clean up all of the welding surfaces yet, this is just a look see for fit-up. I will go over all of the joints with a flap wheel on the die grinder to prep for welding...
Mark