Go Back   DIY Go Kart Forum > Announcements & Suggestions > FAQ & Articles


Closed Thread
Thread Tools Display Modes
Old 01-09-2011, 02:24 AM
sideways's Avatar
sideways sideways is offline
Unfinished projects king.
Join Date: Feb 2009
Location: Perth, Western Australia
Posts: 1,501
Thanks: 50
Thanked 164 Times in 115 Posts
Default Tubing Notcher DIY Method

Have a look here.

Type in the dimensions, print out the PDF you then get, make sure it's 1:1 scale. Cut the template out.

Tape it onto the tube.

Trace the outline.

Grab an angle grinder (called sawz all in America?) with a cutting disk and and a grinding disk, or even better, a flap wheel. Cut it back to the line with the cutting disk first.

Then tidy it up with the flap wheel or grinding disk.


Nice and square too.

Brilliant idea isn't it? I know I'l be using this a lot in the shed! Even better, it costs basically nothing!

*Pics and general idea nicked off another forum*


Attached Thumbnails
DSC_2798.jpg   DSC_2799.jpg  

DSC_2800.jpg   DSC_2802.jpg  

DSC_2806.jpg   DSC_2814.jpg  

The Following 17 Users Say Thank You to sideways For This Useful Post:
2SlickNick (08-07-2016), 3kakr4 (10-22-2016), AltuveRules (10-05-2016), bighead (01-09-2011), Cam (01-09-2011), Doc Sprocket (01-09-2011), Functional Artist (08-20-2016), jroberts (06-24-2014), karte_m0lim (08-06-2014), kenworth85 (01-01-2017), olliecracker (08-16-2011), Oxymoron (10-18-2013), RobertD (01-09-2011), T.Blincoe (04-01-2015), tractor guy (10-31-2013), txluke (03-05-2019), zogthegreat (03-07-2017)
Old 01-09-2011, 02:33 AM
Cam's Avatar
Cam Cam is offline
Nz Petrolhead
Join Date: Apr 2010
Location: Whangarei, New Zealand
Posts: 487
Thanks: 10
Thanked 32 Times in 31 Posts

Makes a clean fish mouth, although i would still tack it with the square in place.

I do a lot of this tubing, in and out of work, and after a while your fish mouth joints can be pretty precise, and i spend a lot of time on mine, my old man used to say just tickle the end to suit, shove the square/magnet on it and tack er up, but i like mine to look professional, like the joint above.

A lot of these small tips could do with being brought up.
Cheers, Cam.
Old 01-09-2011, 11:04 AM
sideways's Avatar
sideways sideways is offline
Unfinished projects king.
Join Date: Feb 2009
Location: Perth, Western Australia
Posts: 1,501
Thanks: 50
Thanked 164 Times in 115 Posts

Originally Posted by redsox985 View Post
How do you make the templates? (possibly a stupid question...)
Go to the link in the first line of my post, type in the variables and print the PDF you will then receive.


Old 01-09-2011, 10:08 PM
redsox985's Avatar
redsox985 redsox985 is offline
Senior Member
Join Date: Mar 2010
Location: PA
Posts: 4,092
Thanks: 57
Thanked 209 Times in 188 Posts

Simple enough! I like the idea.
Old 11-22-2011, 09:41 PM
oldbikerarlo's Avatar
oldbikerarlo oldbikerarlo is offline
Old guy
Join Date: Apr 2011
Location: Marana, Az.
Posts: 449
Thanks: 27
Thanked 50 Times in 47 Posts

Used this last week works great. even 10* angles and two differant sizes
I have a cut off saw, and a welder, anything will fit.
Old 11-25-2011, 07:43 AM
Scout's Avatar
Scout Scout is offline
Join Date: Nov 2008
Location: Indiana
Posts: 541
Thanks: 27
Thanked 86 Times in 61 Posts

chop saw notching
Old 05-15-2012, 08:10 PM
Doc Sprocket's Avatar
Doc Sprocket Doc Sprocket is offline
Join Date: Jun 2009
Location: Ontario, Canada
Posts: 15,677
Thanks: 723
Thanked 2,212 Times in 1,696 Posts

FWIW, I just used this for the first time with total success- had a tricky one to figure out and it ended up being pretty painless...
Treat it as you would an aircraft frame and you should have no problems. -Name Withheld
The Manual- "Just the manufacturer's opinion of how to put this together."- Tim "The Tool Man" Taylor
Put down the wrench, and come out with your hands up!- Me!
Wrench, Wheel, Wreck, Repeat...
Old 02-06-2015, 06:29 PM
RobertD's Avatar
RobertD RobertD is offline
Join Date: Oct 2006
Location: Texas
Posts: 2,884
Thanks: 342
Thanked 1,090 Times in 457 Posts

Another link to this:


Dan Hopper's TUBEFIT Program

Dan Hopper has written a standalone program called Tubefit that gives the same result as the Coping Calculator, when "straight in" is selected. In addition it can also calculate a template for a "straight across" cut which automatically makes a fillet for welding. The latest version is capable of making very large templates if you are willing to do some manual editing of the disc output file. Dan explains how to do this in a text file included in the download. Tubefit also gives you the option to rotate the intersection of the two tubes.

Tubefit is actually a DOS program, but it runs fine on WindowsXP. It can send a postscript file directly to the screen, to a parallel printer, or to a file. This file (postscript or .ps) can then be edited if necessary and sent to any printer.

TUBEFIT.zip (last updated 9/13/08)
Derivation of Dan Hopper's TUBEFIT Algorithm


Closed Thread

Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

All times are GMT -6. The time now is 08:10 AM.