The Official Tube Notching Thread

[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

[wiedemab]

Wow - that's Pretty!

[HarleyR]

Perfection....check it out

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