Sometimes we build handrailing out of 2" round tubing at work for catwalks and stairways. We have been cutting hand railing like this for a while. At work we have an ELLIS brand band saw. You can't beat these saws for the price. Check them out www.ellissaw.com We have also cut tubing like this with our chop saw, but the saw is a lot faster to go from 33 degrees to 90 then 45.
I wrote a program to calculate layout dimensions for pipe saddles, miters, and other. It is at 'www.pipesaddlelayout.com, try it and let me know how it works.
i saw this when you first posted it and looked thru the instructables demo.
we do a lot of 2.5'' ss h-pipe exhaust sytems.
it takes as long to make the h as it does to bend the system.
i tried this out yesterday and it works well for thin wall tubing.
i'm going to make a production jig to go on the bandsaw to notch our new and improved h.
this works for 90 degrees only. i also found the official tube notching thread here that lead me to this http://metalgeek.com/static/cope.pcgi that is good for other angles like a y-pipe for a turbo system
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