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Pipe/tube notching

JonnyMac

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Im notching a few thick pipes, 5mm wall thickness. Its far too thick for what im using but I had some left over.
The hole saw ive got is a relatively good brand but it does have a bit of movement which doesn't sit well with me. Is this normal or should it be solid?
 
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dr_clyde

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Holland, MI
I find hole saws to be relatively crude tools, a bit of runout should be expected. Try it, it'll probably work great for a tubing notch. It all depends on how rigid your setup is.
 

csp

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The movement in the hole saw is because of what it's mounted in isn't it?

I woulnd't think the actual hole saw would/could move. How much is 'a bit'?
 

theoldwizard1

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If you only have a few to do, mark the pipe that needs to be, cut a V into it, clean up with angle grinder and die grinder. Slow, but you can get very good results.

Now if you are going to do a LOT of notches and you need repeatability, accuracy including angle, you need on to these
 

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zkling

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Do you have a notcher to guide it or are you doing this free hand?
 

ez-duzit

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Here's how I did it on 1-1/2" 316 stainless pipe. A heavy duty carbide hole saw with threaded arbor (McMaster-Carr) on my mill.

mill-21_zps3xxglsxc.jpg
 

jimbbski

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Chicago Area
I did a lot of tube notching on DOM steel tubing on my drill press. What I found was that the brand of hole saw effected my success. Some would do a couple of dozen cuts and still be good and other brands would strip off teeth on the first cut.
 

Mr.N

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Mpls, MN
I had great luck with Linux, near two hundred cuts. Keep it cool

Also the cheap harbor freight holder worked well for me


image.jpg


picture097.jpg



.
 
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J

JonnyMac

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Victoria, Australia
So. The hole saw itself is threaded and screws onto the arbor and is located with a couple of pins which locate in the top flange. The movement comes because the threaded section doesnt snug up tight because the primary retention mechanism is the pins.
Im only drilling at 90degs so I am just clamping the tube which is fine.
The fundamental design leads me to think that its very unlikely to be a rigid mount (the hole saw size can be changed using a single arbor).
Ive got a few more to do and I have done a few already but I was wondering how tight the other brands sit.
 

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csp

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Stop using the pins and just thread it up tight. The pins are fine for applications where some runout is acceptable.
 
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zkling

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You really should be using a jig to do this. Otherwise you run the risk of bending the spindle and loosing the chuck. I speak from experience on that one unfortunately.

If you must not use a jig. Punch and then pilot hole the tube for the center drill of the hole saw, then float the tube into position under the hole saw and then clamp everything in place.
 

TauntDevil

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Mesa, AZ
I buy the hole saws from Home depot. Milwaukee I believe. They work good for awhile. I have bought some others before meant for metal specifically but they all seem to go out around the same time so I just buy the cheaper ones from Home depot and when they go out, just buy another. Though I use them for notching tubes and sometimes thin metal for cars. Not sure why it is walking on you as the bit itself shouldn't move at all...
 

mike13u

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So. The hole saw itself is threaded and screws onto the arbor and is located with a couple of pins which locate in the top flange. The movement comes because the threaded section doesnt snug up tight because the primary retention mechanism is the pins.
Im only drilling at 90degs so I am just clamping the tube which is fine.
The fundamental design leads me to think that its very unlikely to be a rigid mount (the hole saw size can be changed using a single arbor).
Ive got a few more to do and I have done a few already but I was wondering how tight the other brands sit.

That movement is movement in the same line of travel that the drill bit spins (in other words, it is not a wobble). All hole saws I have ever used don't snug flush when using the pins. The pins, keeping it off of 'snug,' will help you get the bit off when you are done. Because of the pins you aren't over-tight and the spinning bit isn't getting tighter and tighter on the arbor as you drill. You can 'lock' that blade on that arbor easily without pins on the big holes.

Your results will be fine.

No part of this discussion matters for notching tube or pipe with a hole saw though. The act itself only requires some precision on the cut angle. A little wobble at the end of blade will have little to no effect on your notch. And if it was off a little, all would be corrected at fit-up and tack.

Looking at your picture above, If you want a better way to snug round stock in a mill or drill press vise, get a small V-block and lay it on its side in the vise with the tubing in the V. Then clamp the vise shut with one jaw on bottom of v-block and the other on the tubing. No chance of spin. Also works to hold round stock straight up in the vise. A good investment for the shop :thumbup:

BTW, I think the new Milwaukee Ice Hardened bimetal hole saws that they carry at HD ****. No bueno.
 
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FunkyfullWidth

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Three Rivers, ma
5mm is pretty thick tube. What size diameter is the tube? If your not having luck with the hole saw notch it old school in a chop saw and finish with a grinder. What are you building?
 
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JonnyMac

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Victoria, Australia
Its a long story! but I made some chin up bars for a friend's exercise park so I got the 5mm to prevent any deflection, its 25mm tube. I had a few meters left because he chose a thicker diameter for the squat bars.
So I used the left overs to build a fire pit. The first one was a prototype and I am just tweaking the design but I stuck with the 5mm (massive overkill I know) because the lengths my metal supplier sells it in are 5.4m long and I had part of the frame done and wanted it even!!

Anyway, the hole saw is around 30mm from memory and it works I just wasn't a fan of the movement. . Its got adjustable legs so I can pack it down and take it camping.
 

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csp

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And here I thought you were building something where the fitup of the joint is critical to the strength.
 
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