PDA

View Full Version : Setting up a tubing notcher.

astroracer
07-06-2006, 06:51 AM
Hey guys, I don't know how many of you do your own cage or chassis work but this how I set up my jigs for notching tubing.
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...
http://images17.fotki.com/v322/photos/9/904975/3694678/MVC001F-vi.jpg
From the backside...
http://images17.fotki.com/v14/photos/9/904975/3694678/MVC002F-vi.jpg
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.
http://images17.fotki.com/v14/photos/9/904975/3694753/MVC003F-vi.jpg
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...
http://images17.fotki.com/v15/photos/9/904975/3694753/MVC006F-vi.jpg
Cutting the second notch...
http://images17.fotki.com/v15/photos/9/904975/3694753/MVC007F-vi.jpg

Thanks for looking
Mark
astroracer
07-06-2006, 06:54 AM
I got a little bit done over the weekend. Didn't have a lot of shop time but I did take advantage when I could...
Got the notcher fired up and ran the lower crossmembers through it. It took 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.
Thanks for looking.
Mark
eschoendorff
07-06-2006, 08:02 AM
Wow, some nice ideas here. RIght click, save as.... :beer:
REFLEXX
07-06-2006, 09:32 AM
Astro,

So your saying that the HF notcher works? I've got a lot of HF stuff, some golden, some garbage. The notcher looked weak, but looks like you're having success with it. I'll get one if it works well.
astroracer
07-06-2006, 09:59 AM
Astro,

So your saying that the HF notcher works? I've got a lot of HF stuff, some golden, some garbage. The notcher looked weak, but looks like you're having success with it. I'll get one if it works well.

It works just fine... I got this one off eBay for $28 bucks... Shipped...:beer:
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?PARTPG=INSRAR2&PMAKA=990-0776&PMPXNO=3008824
Mark
astroracer
07-10-2006, 09:35 AM
Just an update for you guys....
I did a quick mock-up of the new lower rails and crossmembers this past weekend to see what the fit-up looks like.
http://images12.fotki.com/v2/photos/9/904975/3766976/MVC015F-vi.jpg
A couple more... The notches came out great and I have some really nice tight fitting joints for Tig welding.
http://images1.fotki.com/v7/photos/9/904975/3766976/MVC017F-vi.jpg
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...
Thanks for looking.
Mark
REFLEXX
07-10-2006, 10:13 AM
Astro,

that's a great write up! I'm adding that notcher to my list.

I'm going to slightly modify the opposing piece of pipe in your design. I'll make mine swivel, because many of my tube joints are at an angle.

Also, here's a link to the thread about bender I made a few months back. A good notcher always needs a good bender: http://www.garagejournal.com/forum/showthread.php?t=3373&highlight=tube+bender
astroracer
07-10-2006, 10:32 AM
Astro,

that's a great write up! I'm adding that notcher to my list.

I'm going to slightly modify the opposing piece of pipe in your design. I'll make mine swivel, because many of my tube joints are at an angle.

Also, here's a link to the thread about bender I made a few months back. A good notcher always needs a good bender: http://www.garagejournal.com/forum/showthread.php?t=3373&highlight=tube+bender

Thanks Bud, I'm glad someone can use the info!
If you look at the pics of the "nesting" piece of tubing you will see it is bolted to the angle plate with two carriage bolts. This lets me set the angle of the "nest" to just about anything I need. I just set an angle finder on the tubing and tighten up the bolts...
I remember the bender thread. I bought a Pro-Tools Series 105 bender last year. I couldn't build it for the price I bought it for and it does a very good job even though it is powered by Mark...
Thanks for the kudo's again.
Mark
SM Racing
07-10-2006, 07:59 PM
My biggest complaint with the HF unit (I have one) is the chintzy mounting setup. I actually did away with the weak single mounting point and mounted the whole thing to a beefy piece of angle iron. Ill see if I can get a couple of pictures

Otherwise it is not a bad piece. I put a grease fitting in the drive block and will probably put needle bearings in there later.