Cutting pipe welding saddle joints

This one is a new one to me:
Apart from fancy and expensive hole saw looking devices, I had never considered using my bandsaw to do these joints. Usually I use my 4" angle grinder freehand and annoy myself by not getting the joints to fit at right angles...
This is from the 6x4 bandsaw Yahoo group:

[ame="http://www.youtube.com/watch?v=s0IPO6Npq2w"]How to make a saddle cut with a band saw - YouTube[/ame]

Making perfect pipe Saddle cuts with a bandsaw or chopsaw
He's not exactly a good presenter, but his instructable (link below video) is pretty good.

Joe

Thanks for posting that Joe. Something to remember should I dust off the welder for a bit of pipe jointing.

BT

Don't abandon that complicated device just yet - I tried with a cardboard tube and got a gap so laid it out on CAD (for those who doubt the need for 3D modelling, this is one application that would be much easier).
Firstly, the long shot. This is scaled at OD=30mm, wt=2.5mm

Attachment 206603

However, when you zoom in

Attachment 206604

There is a clash which in reality would end up as a slight gap. It would be better with thinner tube I expect. Interestingly the video refers to 28 degrees, but he found that 30 was better. When I measured the angle of the cut, I got ...28 degrees. 30 degrees would reduce the clash but increase the gap near the top.
The gaps are not large (fractions of mm) but do show it is not a perfect fit up. Still, next time I have to do some saddle welds, I might try it just to see what reality is like (rather than use that #@*%& hole-saw device

Michael

for production runs on school intergration ramp balustrading i use 28* cuts regularly,the gaps are totally irelavent to a mig welder and also a stick welder in a pair of good hands.this angle works also when useing differant pipe sizes such as 30 od leg to 50od rail.will also work on slight inclines say up to 50mm in a metre.cheers danny

Very timely as I'm about to cut the ends of a pipe of pipe for the lifeline stanchions for my boat. I know how to do it the 'proper' way but it's slow so I don't, just use an angle grinder and weld. This way should be quick and give better results on the fitup. Thanks.

PDW