I have 1 5/8" header pipes to cut at 1" intervals with a 15 degree angle on one end. I discovered that toilet paper cardboard rolls slide nicely over the pipe so I cut one end of the roll at 15 degrees. Then for every piece, I slide the roll over the pipe and mark it. Whether the straight cut side or the angle cut side, I get a perfect mark every time. And because I am cutting the pipe by hand (I don't have a big bandsaw), I score the pipe all the way around with a few passes of the hack saw first and just keep repeating until I'm through. It takes a while but faster than I thought it would be. I think I could cut and file about 4 or 5 an hour. I have over 100 to go I figure but I get a nice clean cut with little waste. I hope this helps somebody else thinking about making their own headers.
That's how I used the rolls too... I looked around at different ways to cut angles in tubing for the headers I did for my Essex and like many people out there. I couldn't afford to spend money on a "1 time tool", so I used a paper roll as a template before I cut the pipe
I must ad that I did use air tools to get the cuts quicker though...
something that may help the guy who does roll cages or similar type work are these.... they come in different sizes just slide the tool against the part and it forms to the shape of the other pipe... slide it back and mark the pipe you're cutting...
-- Edited by 30-S6 on Sunday 10th of April 2022 08:05:06 AM
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Thank you guys. I did try using a cut off wheel on my angle grinder but the cut wasn't as precise or neat and required a lot more cleaning up to ensure a 15 degree angle was maintained. The hacksaw was worth the time and effort but I'd much prefer a $1000 bandsaw. I find improvising with things like toilet paper rolls make building more fun. Creativity from from waste (pun intended). The pipe master is a nice idea but the toilet paper rolls allow me to save and I save every penny for the big stuff when I can. Rear suspension is next on my list of big stuff. Air or mechanical, I can't decide. Air is prone to failure and mechanical is so unique. Just have to sort out how. But for now, having a ball with the headers. Took all winter so far but the joy is in the build for me. Thanks again everyone.
Thank you 123pugsy but I have an $800 chop saw that I bought decades ago. It does nice angles vertically and horizontally but I thought a bandsaw was necessary because that's what is used in every video I found. No idea why but nobody used a chop saw that I could see. But if I can use that, I will. Much easier and precise. Thank you for that.
Thank you both ! I watched the video & now I know why no one uses a chop saw to cut pipe. I tried a fibrous blade but now I know I can use a chop saw if I slow the blade down. Cool. (literally). Great idea. Thank you again. I do like my chop saw. It got me through a lot of big wood projects successfully. I'll have to see what other videos this guy has done. Could be a good source for other tips too.