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...



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...




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.



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.



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.





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

[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.

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

[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.

[Streetwerkz]

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

[Streetwerkz]

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?

[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