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Coping / saddle cuts in aircraft tubing

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Joined
Jan 3, 2014
Messages
6,143
Location
Wisconsin
Figured I'd start a thread on a pet project I'm working on. I'm just about finished. This tool and method isn't for everyone, this is more of a "next level" kind of a tool. Hand tools work just fine.

I've snipped tube ends with success, used files too, and grinders, and that lame "joint jigger". For a couple years now I wanted to set myself up with a automated shaping device of sorts. Well, I use the automated term loosely I guess. Basically I wanted something close to the accuracy and fit of a CNC without paying $2k for a shop to do it.

Here's what I have so far as well as a test run. I have a system thought out for doing accurate and consistent angles but for today I just held it by hand using my eyeball.

The belts are 60 grit Norton Blaze 2" wide. Still adjusting my machine but it's going well.

This joint took no more than 3 seconds and the fit is flawless.

The best welded joints ALWAYS share a relationship to the quality and accuracy of the saddle cut....including the angle in the tube wall, which you can't get with snips.

Is this necessary? No. But now I have a great shop tool with adjustable platens and it's cheaper than CNC.
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