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Tube Notching

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Mar 29, 2008
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Hi all,

I'm just curious, what techniques have you used to fit tubes together that hasn't involved an elaborate jig or a credit card? I was reading a guide to tig welding 4130 tubing and they quoted the fitment tolerances of a certain autosports team, only "Perfect and almost not perfect" joints are acceptable. My old technique of using a hacksaw and the rounded off corner of a bench grinder wheel didn't quite get me to that standard but I was gas welding so it was passable..

Anyone using sanding drums in a pneumatic die grinder or burrs? Maybe a nicely worn angle grinder abrasive wheel? Still have all ten fingers?

What other strategies, other than just taking your time, are out there? Thanks and bonus points for pics

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