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Hi

There's many ways and many machines and tools for tube notching.

Easy way is to use drillpress and holesaw, but if you don't have them, you need to find another ways.

Actual cutting is the easiest part, specially if you have a template for drawing the lines for cutting.

Video shows my easy way how to draw a template for 90 degree tube notch.

Step 1: Cutting / Forming ...

I like to make cuts with the angle grinder using cut off wheels, the just smoothen it with the flap wheel.

I use regular pencil for drawing the lines, it doesn't disappear from the heat produced by cutting and grinding...

Step 2: Cutting / Forming...

Of course you can use other tools for forming too.

Drill / rotary tool equipped with tungsten carbide cutters, grinding stone, sanding drum..Works nicely too.

You can use even jigsaw, (sometimes you might need to shorten the blade).

For shaping ventilation ducts etc.. i have found jigsaw and reciprocating saw to be very suitable. ( no dust inside the tube, or burnt zinc coating.)

Ways are many, and now its easy task, when you have a template for it.

<p>I have a favorite way, using my bench mill/drill, and chucking a milling cutter the SAME diameter as the tube. Then simply mill straight into the end of the tube a distance of half the diameter! But you must be centered on the center line of the tube you are notching. Perfect fit every time! Lee Robinson West Palm Beach</p>
Yep. That is a great way. This method is for those who don't have all those tools. Personally i need to make noches couple times in a year, and usually all of those are with different size. In my hometown, its really difficult to find good holesaw's for metals, and if you find one, its really expensive.
<p>Aha! A paper template! Brilliant: that'll help next time.</p><p>That's for a 90 degree T joint: I suppose the template could be modified for other angles too?</p>
It should work with other angles too, i havent actually ever needed to make any other than T- notches. Needs to take a better look for that.

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Bio: Just a fellow who want's to learn new tricks and skills.
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