Tubing notcher suggestions

[Jason280]

I am going to be doing a few tubing projects, mainly front bumpers and tube doors for a Jeep, and have decided a tubing notcher will be very helpful. I'd prefer a setup that will work with a drill press, and will likely be using tubing from 1" to 2.5" in diameter (likely limited to 2").

Any suggestions on a decently priced notcher that can be used with a drill press? I have a decent sized 13" bench model that should be more than adequate, just need to find a notcher.

For those than use them routinely, anything specific I need to pay attention to or look for in a notcher?

 

[zkling]

Budget? The best IMHO is a home made one. Outside of that the JD2 is a nice unit, but kinda pricy.

https://www.jd2.com/p-62-tn-100.aspx

You will be at the limit of your 13" bench drill press. Holes saws take quite a bit of torque and have a tendency to grab thin sheet metal. Notchers can be hell on a drill press. I personally prefer to just use a corded electric drill and mount the notcher to a bench.

 

[astroracer]

I have been using a Harbour Freight tubing notcher for a long time. Never had any issues with it. Even doing 2" x 1/4 wall DOM. A drill press will work but I set my notcher up clamped to a 90* angle plate. This is a simple to set up and doesn't require a lot of thought... For making 90 degree (or any degree) cut this is the berries and it pretty well gaurantees straight notches.

From the backside...

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.

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...

Cutting the second notch...

Thanks for looking
Mark

 

[Jason280]

Mark, thanks for the pics and information!

 

[astroracer]

No problem, I posted this stuff years ago, it's nice to dredge it back it up once in a while.
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, you'll have some quality notches that fit well enough for Tig welding.
Mark

 

[DieselSaves]

I think the Baileigh unit is price competitive with the JD2 one with a few better features. It has a solid clamping system that can even clamp on an existing bend.

I've been trying to decide whether to go good now or try the HF and upgrade later.

 

[roachcoach]

I would also take a look at the JMR notchers. They have the very pricey JMR TN1000, and then there is the less expensive JMR Raceline TN300. These notchers will allow you to notch around a 210 degree arc. Also, they allow for offset notches up to 1".

 

[theoldwizard1]

The biggest issue with the HF unit is that the centerline of the hole saw does not line up with the centerline of the tube. Most guys cut a shim out of sheet metal to go under the clamp base.

Also, use a GOOD quality hole saw.

 

[BD1]

I would go with the Baileigh TN- 250. Here's a posting on the Welding web site. Worth viewing.

http://weldingweb.com/showthread.php?289841-tube-notcher

 

[R.Anderson]

If your drill press is rigid enough a cross slide vise with v-jaws and a good bi-metal hole saw works. With this setup I can notch pipe up to 2" OD, can side notch pipe as well. Make sure you lock the ways prior to cutting.

I like your setup astroracer, especially make for making numerous parts with the same dimension. I just might have to incorporate that idea

 

[raboyto2]

Lots of good advice on the tube notchers, but just gonna add this here.

Circulating coolant that I made that helps keep things clean and hole saws last longer .

An automotive washer fluid pump (powered by a computer power supply) sprays coolant on the pipe and hole saw. The nozzle is from Homedepo, a water irrigation nozzle. The flex shaft is from a magnet from Princess auto with small tubing pushed inside. Just an old windshield washer fluid jug for a tank.

What I think is neat is the way the metal chips are dealt with. Magnets stop the metal chips from recirculating. There are two trays stacked on top of each other. The bottom tray has magnets glued to it and the top tray is just free floating. Once your are done notching, you just take the top off the bottom tray and dump it in the garbage. There is still a small filter just in case something gets through.

The system is using water based lubricant.

 

[R.Anderson]

Lots of good advice on the tube notchers, but just gonna add this here.

Circulating coolant that I made that helps keep things clean and hole saws last longer .

An automotive washer fluid pump (powered by a computer power supply) sprays coolant on the pipe and hole saw. The nozzle is from Homedepo, a water irrigation nozzle. The flex shaft is from a magnet from Princess auto with small tubing pushed inside. Just an old windshield washer fluid jug for a tank.

What I think is neat is the way the metal chips are dealt with. Magnets stop the metal chips from recirculating. There are two trays stacked on top of each other. The bottom tray has magnets glued to it and the top tray is just free floating. Once your are done notching, you just take the top off the bottom tray and dump it in the garbage. There is still a small filter just in case something gets through.

The system is using water based lubricant.

Now thats integration another great idea I might have to incorporate