white90 Posted January 28, 2007 Share Posted January 28, 2007 Tips/hints advice? don't have a notcher so it will be paper grinder and saws any advice greatfully recieved Quote Link to comment Share on other sites More sharing options...
LandyManLuke Posted January 28, 2007 Share Posted January 28, 2007 have you got the program for making notch templates? Quote Link to comment Share on other sites More sharing options...
ciderman Posted January 28, 2007 Share Posted January 28, 2007 Simple , Tony use a hole saw the same size or a couple of mm smaller than the tube , Find the centre of the tube and drill it , leaving you with a lovely bird mouth. will show you tommorow if you like. Quote Link to comment Share on other sites More sharing options...
white90 Posted January 28, 2007 Author Share Posted January 28, 2007 Jase yes please all help very welcomed! could you PM the post code for tomorrow so I can shove it in Tom Tom Found a brand new 51mm starrett hole saw so that'll do the job Quote Link to comment Share on other sites More sharing options...
ciderman Posted January 28, 2007 Share Posted January 28, 2007 The Tube is 42.4 mm , I will have a look in the yard tommorow im sure there might be a 38mm starret I could lend you. Quote Link to comment Share on other sites More sharing options...
Hybrid_From_Hell Posted January 28, 2007 Share Posted January 28, 2007 Jase yes please all help very welcomed!could you PM the post code for tomorrow so I can shove it in Tom Tom Found a brand new 51mm starrett hole saw so that'll do the job Tony Have a play with this : Whooooopeeeee Dooooooo ! Nige Quote Link to comment Share on other sites More sharing options...
LandyManLuke Posted January 28, 2007 Share Posted January 28, 2007 slightly different, stand-alone, downloadable version here Quote Link to comment Share on other sites More sharing options...
white90 Posted January 28, 2007 Author Share Posted January 28, 2007 thanks all. James can you download these so we can make some templates? just need to measure the tube of your cage IIRC mine is 48mm the bars are 42.4 wall thickness to be checked tomorrow Quote Link to comment Share on other sites More sharing options...
Les Brock Posted January 28, 2007 Share Posted January 28, 2007 one to download and use to print here http://www.btinternet.com/~les.brocklehurst/Tube.html Quote Link to comment Share on other sites More sharing options...
marsie Posted January 28, 2007 Share Posted January 28, 2007 Dont forget the photos Tony,want to see your interpretation of wing bars Paul Quote Link to comment Share on other sites More sharing options...
Jon White Posted January 29, 2007 Share Posted January 29, 2007 I did it the hole saw method when i did my roll cage - took bluddy hours!!! When I did my roo bar i just did it with the grinder. Much much quicker and the results are the same - just keep trial fitting it until its perfect. Abrasive flap wheel in the grinder is best I found. HTH Jon Quote Link to comment Share on other sites More sharing options...
Daan Posted January 29, 2007 Share Posted January 29, 2007 Tube notching can be really easy: a 90 degree tube notch is in fact a tube straight cut twice at 45 degrees. Have a look at a notched tube and this is a very close approximation of the shape. This is how I did all mine. It needs a bit of fettling afterwards, because this method assumes 0 wall thickness, which you obviously havent. if the angle is not 90 degrees, say 45 dgrees, the cutting angle will be 22.5 and 67.5 degrees and so on. once you get the hang of it, its easy! (as usual..). Daan Quote Link to comment Share on other sites More sharing options...
Turbocharger Posted January 30, 2007 Share Posted January 30, 2007 Daan - although Tony said notching, I think he meant birds-mouthing - forgive him, he's from Somerset... Quote Link to comment Share on other sites More sharing options...
white90 Posted January 30, 2007 Author Share Posted January 30, 2007 TC your so sharp! one day you'll cut yourself PS we have used a 51mm holesaw to good effect. Quote Link to comment Share on other sites More sharing options...
Turbocharger Posted January 30, 2007 Share Posted January 30, 2007 I read the original post and assumed you meant birds-mouthing, so I had a moment when Daan said you could do it with two straight cuts... I was trying to think in 3D but only using a 2D-spec brain. Quote Link to comment Share on other sites More sharing options...
4.6v8lwt Posted January 31, 2007 Share Posted January 31, 2007 It is possible to do it by using two straight cuts, there is a good article on the Pirate4x4 website which explains it all. Quote Link to comment Share on other sites More sharing options...
Astro_Al Posted January 31, 2007 Share Posted January 31, 2007 I think there is a certain amount of confusion here. As I understand it, everyone is talking about the same thing, but using different words for it. Notching / fish-mouthing / birds-armpit / elephants-genitalia... whatever, it's the curvy bit at the end of one tube which allows it to butt up against another tube perpedicular to it with no gaps. Daan (et al) is right - the answer is: Yes! It can be done with 2 straight cuts. I was gonna suggest you use a chop saw if you have no notcher etc. It can come out pretty perfect if you get the 2 angles right - maybe a quick clean up / fettle with a grinder, and just weld it on! Al. Quote Link to comment Share on other sites More sharing options...
Daan Posted January 31, 2007 Share Posted January 31, 2007 Daan (et al) is right Al. Cheers, I dont hear this very often and I wasnt going to start a row over it, because I dont care. But, yes with so many things simple is best. Daan Quote Link to comment Share on other sites More sharing options...
Astro_Al Posted January 31, 2007 Share Posted January 31, 2007 Cheers, I dont hear this very often and I wasnt going to start a row over it, because I dont care. But, yes with so many things simple is best.Daan No you're absolutely bang on - I think it's hard for a lot of people to visualise how a straight cut through a bar results in a lovely curved notch that butts up against another tube perfectly, but it sure does - I've done it myself. Practice a bit though, or use a calculator - if you are doing wonky angles the cut often needs to be at a pretty unintuitive angle... If I can be bothered, I'll post a link to the thread on Pirate about it... Don't hold your breath... Al. Quote Link to comment Share on other sites More sharing options...
Turbocharger Posted January 31, 2007 Share Posted January 31, 2007 OK Daan, sorry for misunderstanding. I've still got my 2D head on though, I don't understand how you can get the proper 'sine curve' profile into a round tube with 2 straight cuts. In my head, that'd be the way to join a tube to some triangular bar - as I see it you need to project a circle onto the pipe (as viewed from the side). Cue a 1980s diagram in Paint (I hired an 8 year-old to help me with this part) Is it just a case that 2 straight cuts is near enough to tidy up with a grinder and make up the gap with an unsteady hand on the welder? I'm not saying I don't believe you, I just don't understand it and it's bugging me now. Quote Link to comment Share on other sites More sharing options...
LandyManLuke Posted January 31, 2007 Share Posted January 31, 2007 the two straight cuts are an approximation, have a practice with a couple of bog rolls and you'll work it out, in fact i might go and do it to help you out. Quote Link to comment Share on other sites More sharing options...
Mark90 Posted January 31, 2007 Share Posted January 31, 2007 Think about it.... Take tube and make two 45° cuts in an X (as viewed from above) such that you end up with a point on the end of the tube rather than a triangular notch in it. Now turn the tube through 90°. What shape is the notch? I say it's semi circular. Quote Link to comment Share on other sites More sharing options...
Turbocharger Posted January 31, 2007 Share Posted January 31, 2007 I'm with you - I've edited my diagram. The issue was that I was making two cuts as the blue 'wedge' shows (and getting a much worse approximation), not as the purple plane represents. Like I said, I just didn't have my 3D head on... Cheers guys, esp Mark (it hurts to say that) for the clear explanation. Quote Link to comment Share on other sites More sharing options...
LandyManLuke Posted January 31, 2007 Share Posted January 31, 2007 I've just been and done it, that's the state of interesting things to do here.... As you can see, it's not perfect, but it's not past a bit of fettling with the grinder. Quote Link to comment Share on other sites More sharing options...
Mark90 Posted January 31, 2007 Share Posted January 31, 2007 Cheers guys, esp Mark No problem John, always glad to help I know this sort of thing doesn't come naturally to engineering graduates Quote Link to comment Share on other sites More sharing options...
Recommended Posts
Join the conversation
You can post now and register later. If you have an account, sign in now to post with your account.
Note: Your post will require moderator approval before it will be visible.