I ran across this nifty tube coping calculator on another board and had to share it here. Basically after you enter the specifics on the tube you are working with and the angle of intersection you want, it prints out a flat template that you can cut and wrap the tube with that shows the exact place to cut without the aid of an expensive tube notcher. Perfect for roll bars and cages. Hope this helps someone. . .

Tube Coping Calc.

I don't know when this may come in handy, but I'll save the link.

Thank you.

A hole saw of the same diameter of the tube, a drill press, and a good drill vise do the trick.....a good eye for angles & a protractor help.

OR a $4-500 machine to do it.

The coping printout is nice, but after notching hundreds of tubes, I've found that a good eye, permanent marker, and an angle grinder can make equally nice joints in about the same time.

I have used every method known to notch tube,
a tube notcher ( even a H.F.) is by far the fastest (1-5 minutes) and most reliable, under 60*. It is my go to, even over a mill, unless the mill is already set up

The metalgeek tempelets are so nice to use for hand shaping over 60* ( 0-30*). Also great for blending multiple tube intersections. It is not that easy to get perfectly straight though, and as hard as you try it will no fit as well as a notcher or mill.

I used that notching calculator when doing the wastegate piping for my exhaust...worked perfectly!

-Britain

I used this when I built my car...

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