The Official Tube Notching Thread

[BAILEIGH INC]

Hey guys, I'm going to start a tube notching thread, so.....

If you have any questions, input, tips or tricks or horror stories about notching tube. The good, the bad and the ugly, here is the place for it.


Hole saw notchers......good or bad?
Best hole saw?
Abrasive notching vs. end mill style notching?
How many notches do you get from an abrasive belt?
Notching with a chop saw?
Best way, worst way to notch tube?
Software to help with tricky notch angles?
Notching schedule 40 pipe.....best way?
Home made notchers, lets see em!

[brrymnvette]

I've got a Harbor Freight/Central Machinery notcher. The cheap $40 one. I've only used it a couple times on 1-1/2" sch40 steel pipe. Need to get it in a drill press b/c pushing it by hand sucks. I also have to shim out the pipe holder to get it to center on the hole saw. But for the price I can't complain. I'd love to have the scrilla to buy a better unit, but the price goes up astronomically to get a decent one.

[astroracer]

I use the HF notcher also. Setting it up as I do I have no need for a drill press and this set up allows for a lot of freedom in setting up angles.
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 or time...

https://static1.pt-content.com/images/noimg.gif

From the backside...

https://static1.pt-content.com/images/noimg.gif

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.

https://static1.pt-content.com/images/noimg.gif

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...

https://static1.pt-content.com/images/noimg.gif

Cutting the second notch...

https://static1.pt-content.com/images/noimg.gif


It takes 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.

https://static1.pt-content.com/images/noimg.gif

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.

https://static1.pt-content.com/images/noimg.gif

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.

https://static1.pt-content.com/images/noimg.gif

https://static1.pt-content.com/images/noimg.gif

And in response to a question about how well the HF tubing notcher works...

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

https://static1.pt-content.com/images/noimg.gif

[astroracer]

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 tight fitting joints for welding.
https://static1.pt-content.com/images/pt/2006/07/MVC015Fvi-1.jpg
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

[BAILEIGH INC]

Castrol wax lubricant

I have never heard of using this in a notcher, but good info. Thanks!

[BAILEIGH INC]

Perfection....check it out

https://static1.pt-content.com/images/pt/2010/01/attachmentphpattachmentid494271stc1d1263-1.jpg

[wiedemab]

Wow - that's Pretty!

[HarleyR]

Perfection....check it out

https://static1.pt-content.com/images/pt/2010/01/attachmentphpattachmentid494271stc1d1263-1.jpg
I see someone checks out Race Dezert too.... amazing fabricators over there

[chassisguy]

I use the JD2 Beast its a holesaw style, i used several different types of notchers and this is the most versitile one. The reason i like the holesaw style is because its cheaper to replace and can find at any local hardware store. I used the motorized notchers with the endmills at Jerry Bickels and they arent as versitile, For example you can notch in the center of a bend with the beast and not the motorized one. Heres a link....
http://www.jd2.com/shop/custom.aspx?recid=5

[BAILEIGH INC]

I see someone checks out Race Dezert too.... amazing fabricators over there


Yep, thats where I got the pic.

Amazing work!

[BAILEIGH INC]

Perfect for cages, check out our new addition!

http://www.bii1.com/notchers/tube-notcher-tn250.php


:smoke:

[Streetwerkz]

We have an abrasive notching unit with a 3 1/2" at 30 degree tube notching capacity, which we love.

I have been traveling to another shop lately werking on a top sportsman chassis with a shop that doesn't have a notcher.
So I need a "traveling" notcher now

I was thinking hard about the "the beast".... after seeing the new Baileigh notcher :jawdrop: my mind is made up!!

Josh

[BAILEIGH INC]

We have an abrasive notching unit with a 3 1/2" at 30 degree tube notching capacity, which we love.

I have been traveling to another shop lately werking on a top sportsman chassis with a shop that doesn't have a notcher.
So I need a "traveling" notcher now

I was thinking hard about the "the beast".... after seeing the new Baileigh notcher :jawdrop: my mind is made up!!

Thanks Josh!

Check out this movie of our new notcher

Baileigh Tube Notcher TN-250 Video (http://www.bii1.com/videos/tubing-notcher-tn-250.php)

https://static1.pt-content.com/images/noimg.gif

[Streetwerkz]

After talking to Shane, and getting a price quote I'm SOLD!!!

I can't belive what a value this is!!

[BAILEIGH INC]

"V" block vises are nice........correct. But the are very limited.
Here are some pictures of what we can do with the TN-250 radial vise. I think the pictures speak for themselves.
https://static1.pt-content.com/images/pt/2010/04/untitled4-1.jpg?t=1272662687

[Streetwerkz]

:kewlpics: and to think I was excited when I thought it just werked on round tube!!!

[Streetwerkz]

:kewlpics:and to think I was excited when I thought it would only werk on round tube!!!

[Riderz Cycle]

I have a pro-tool notcher works very well, and heavy duty. they have a good selections of tools for racers...link below

http://www.pro-tools.com/hsn501i.htm

[fordsbyjay]

So what is the cost on one of these TN-250?

[coolwelder62]

I ordered my TN-250 notcher 3 weeks ago.Waiting for it to show up.I may throw my mittler bros. notcher in the trash when the tn-250 notcher shows up.I have waiting to start my new camaro sub frame project until it shows.Please ship ASAP!!!!!!!.Scott.

[brrymnvette]

I ordered my TN-250 notcher 3 weeks ago.Waiting for it to show up.I may throw my mittler bros. notcher in the trash when the tn-250 notcher shows up.I have waiting to start my new camaro sub frame project until it shows.Please ship ASAP!!!!!!!.Scott.

Don't throw it in the trash! Give it to one of us less fortunate gearheads!

[coolwelder62]

WOW!!! ups just showed up w/my new TN-250 notcher.Man is this thing built HD.I really got my money's worth in this thing.Can't wait to used it thurs.Totally happy so far.

[fordsbyjay]

WOW!!! ups just showed up w/my new TN-250 notcher.Man is this thing built HD.I really got my money's worth in this thing.Can't wait to used it thurs.Totally happy so far.

Did you get if from baileigh or somewhere else? Just wondering how many bones they cost.

[chassisguy]

Shane from Baileigh Industrial just set me up with this new unit called the TN-250, and i gotta say it blows anything i've used outta the water...i will make some youtube demonstration videos soon. Is there anything in particular you guys would like to see. Just post up questions or what limits you wanna see me push with this amazing product. thanks Mickeys Chassis Works

[coolwelder62]

Got mine from Vanslant $525.00 $ 25.00 shipping.It was drop shipped from MFG.

[BAILEIGH INC]

Got mine from Vanslant $525.00 $ 25.00 shipping.It was drop shipped from MFG.

Any feed back?

[BAILEIGH INC]

Let's see some pics guys!

[DynoDon]

I have had and tried many different notchers over the years. From Mittler to the Ye Old Joint Jigger. I always end up going back to doing them by hand on the Burr King belt sander! It is much faster, I can play with angles very easily and have done thousands of notches this way when building cages or complete Off Road Chassis, some of which have been on Baja race winning cars.
Just works much better for me. And I know a bunch of guys in the industry that do the same. I was taught this method by Jerry Penhall of Penhall Fabrications in Costa Mesa when I worked for him many years ago.

[coolwelder62]

The TN-250 is going to be a very useful. It will not replace my mittler bros. but will do some nocthes that the mittler wont. Having the tn-250 & mittler bros notcher now is like having my cake and eating it too.The tn-250 is a very super heavy duty piece equipment. You will not find a nicer built notcher for the money. For the home shop fabricater this is the perfect tool. And the nice thing is they dont have it over priced.If you look into buying this tool, also look at the deep hole saws that vansant has to offer.They make cutting those long angle cuts easier.As soon as I learn how to run the notcher & hold the camera at the same time I will posts some photo's.Scott.(This is not been a paid advert.)

[BAILEIGH INC]

The TN-250 is going to be a very useful. It will not replace my mittler bros. but will do some nocthes that the mittler wont. Having the tn-250 & mittler bros notcher now is like having my cake and eating it too.The tn-250 is a very super heavy duty piece equipment. You will not find a nicer built notcher for the money. For the home shop fabricater this is the perfect tool. And the nice thing is they dont have it over priced.If you look into buying this tool, also look at the deep hole saws that vansant has to offer.They make cutting those long angle cuts easier.As soon as I learn how to run the notcher & hold the camera at the same time I will posts some photo's.Scott.(This is not been a paid advert.)

Right on man, thanks. :cheers:

[Scott Hightower]

Just a quick comment for any newbies to roll cage fabrication. For the best structural weld it is important to have a perfect fit. If the notch angle is off practice a bit with scrap tubing until you get the proper angle.

As a last resort, if you have a small gap in one area you can lay a piece of welding rod in the gap before welding.

Scott
Fab Manager

[exwestracer]

I have had and tried many different notchers over the years. From Mittler to the Ye Old Joint Jigger. I always end up going back to doing them by hand on the Burr King belt sander! It is much faster, I can play with angles very easily and have done thousands of notches this way when building cages or complete Off Road Chassis, some of which have been on Baja race winning cars.
Just works much better for me. And I know a bunch of guys in the industry that do the same. I was taught this method by Jerry Penhall of Penhall Fabrications in Costa Mesa when I worked for him many years ago.

It's amazing how many people (me included) come back to the hand method :naughty:? after it's all said and done... My previous favorite was using a fixture on the tool rest of a lathe and putting an end mill in the chuck. Now I cut everything with a "suicide wheel" on a Bosch angle grinder. A BIG disc sander works great too, I've just found that in most cases it's easier to take the tool to the tube than the tube to the tool.

When working with 4130, I don't even cut the tube off first; I just mark out the notches and use the notch cuts to sever the piece. I typically need 2 of everything, so the next end is mostly prepped as well. Cuts down on a LOT of waste.

[BAILEIGH INC]

Did some test notches today for you guys......

https://static1.pt-content.com/images/pt/2010/07/IMG_0917-1.jpg
https://static1.pt-content.com/images/pt/2010/07/IMG_0915-1.jpg
https://static1.pt-content.com/images/pt/2010/07/IMG_0914-1.jpg
https://static1.pt-content.com/images/pt/2010/07/IMG_0911-1.jpg
https://static1.pt-content.com/images/pt/2010/07/IMG_0910-2.jpg
https://static1.pt-content.com/images/pt/2010/07/IMG_0907-1.jpg
https://static1.pt-content.com/images/pt/2010/07/IMG_0902-2.jpg
https://static1.pt-content.com/images/pt/2010/07/IMG_0918-1.jpg
https://static1.pt-content.com/images/pt/2010/07/IMG_0903-2.jpg
https://static1.pt-content.com/images/pt/2010/07/IMG_0917-1.jpg

[coolwelder62]

Shane; that is the reason I bought this notcher.It would take hours to do those notches by hand w/a grinder or belt sander.I have all ready done that type of work w/my awesome TN-250.I got the extra deep hole saws & only have to cut the slug in half once on those super deep notches.I couldn't be w/o my TN-250 now.The best $550.00 dollars:cheers: I have spent in the shop in year's.Scott Mock

[BAILEIGH INC]

Shane; that is the reason I bought this notcher.It would take hours to do those notches by hand w/a grinder or belt sander.I have all ready done that type of work w/my awesome TN-250.I got the extra deep hole saws & only have to cut the slug in half once on those super deep notches.I couldn't be w/o my TN-250 now.The best $550.00 dollars:cheers: I have spent in the shop in year's.Scott Mock


Right on, let's see some pics!