I made a quick halfassed one today at work because our bandsaw wont hold a pipe in place at such a sever angle. I will get pics soon. Anyone wanna post theirs?

 

only made twinscroll collector before, jig was just a 2x4 clamped down at the right angle and the pipe clamped against it. after its cut spin the pipe around and voila one sides done and it fits perfect. honestly tho as long as ive been reading this welding forum ive prolly only seen 1 maybe 2 pictures of jigs posted, top secret stuff ya know.

 

i weld my pipe to an other one tight in the saw wise

 

Can you get a pic of MS paint one, haha

 

Mine isn't very good, but it does the job. I'm still thinking of ways to make a better one.



Unfortunately, I don't have any other pictures of it, but you can see it next to the intercooler in this pic :



Made this yesterday :

 

I need my flanges ordered from Canada, its taking forever to get em!

ag, goes that little sheet metal pinch the pipe against the square tubing?

 

Sheet metal? There's no sheet metal. The entire thing is made of 1x1x1/8" square tubing. Maybe the carpenter's square is throwing you off?

 

i only have a ok pic ill try to get you more. this was when i was testing how deep i wanted to make the cut.

 

sorry to quote with your picture, but does the saw you use work good for cutting the SS sch10 and 40 tube? i have one and never thought to use it for that tubing! nice

 

god I love those v band collectors....to bad I just bought a new turbo and manifold 6 months ago

 

for one thats pipe, and yes it will cut it, i have one, but it is messy and loud. i use it if i have somehting in my bandsaw.

or else i stay away from my chop saw.

 

I don't have pics of mine anymore, but IMO mine is better than anything I've seen posted here ever.

I used an expandable bushing, that uses a bolt and nut. On the back of the expandable bushing I welded a perfectly square endplate that was the width of the OD of the sch10 and perfectly square. I insert the bushing, expand it, and I instantly have a 90 degree turning reference on the end of a round pipe. I then used a piece of L shaped steel for it to mount in tightly. All but absolutely perfect everytime...and sometimes they are dead perfect....on a Harbor Freight bandsaw.

 

mind posting a pic? I understand the expandable bushing and square part, I just can't picture how you are holding it in the bandsaw with L shaped steel? You mean angle iron? and you clamp the pipe against it?

 

I'm stealing your idea for how to mount the piece of piping onto the chop saw. easy to calculate the final angle for the collector and cut it precisely by using your method. Thanks!!

 

Your welcome and yes it cuts it perfect and when everyone says to over angle your second turn to compinsate for blade deflect i didnt have that problem at all i actually made it level and cut and it came out perfect

 

TurboFocus....the issue with yours is it's nothing more than a clamping system. That's hardly a jig. Nothing is there to accurately turn the piece. Also, how do you accurately change angle for various styles of collectors (3", 4", 5", etc)?

I'm not trying to get on your stuff...I mean, for a chop saw you've done well. I just want to clarify that that isn't a jig...it's merely a clamping system. This is just the step up from sharpies and vice grips.

 

ouch. He posted the jest of what I was asking. Thanks focus. I Guess i should have made my title a little less direct

 

Actually he wrong but its because he cant see the whole thing i do mostly 3.5 inch collectors so i have it set up that way now and the way its held is at a 11 degree angle for my cut. you make one cut then turn the pipe 90 degrees i have a dial indicator and a level to check it. the whole jig slides left to right so if i need to have a 4in collector made i slide the 4in pipe to my mark then slide the jig over a 1/8 inch.

 

i dont have any collectors made at the moment but they line up so nice

 

who can make me a jig to do 3-1 merge collector

 

I can make you a collector or the jig, whichever you like. I see you are on long island. Let me know if you are serious.

 

I wasn't trying to be dickish...don't get me wrong. I was just saying, that it appeared to just be a clamping system, not a true jig. Jigs should be something that can accurately reproduce a unit while eliminating, as much as possible, user error.

Using a dial indicator and levels is certainly going to result in the finished product, but that's not truly what you want out of a jig. IMO a jig not only accurately allows you to achieve the end result, but to do it in a speedy and fairly easy fashion.

My first jig used a similar setup, and don't get me wrong....it cut very well. The same issue existed though. I had to turn it, use a reference level between the blade and the first cut, etc. It worked well, but it still was pretty time consuming. I didn't care much in the beginning, but slowly, creating collectors became a pain. That's when I set out to make a jig that was simple. Put the piece in, hit the power button, unbolt it, turn, bolt it again, hit the power. The endplate that was perfect square was all the difference in the world....aside from saw setup.

To each his own though...if you like how yours works, then your good to go.

 

 

Has anyone figured out a jig to cut bent tube? We spent some time on this a year back or so for cutting some 18 degree bends into 4-1 collectors for a production job.. and the result was less then desireable. We ended up using off the shelf formed collectors instead.

If you've got one or have design for one - we pay top dollar for R&D.

 

just make a plan for your jig and do it
if you are really unable to do it go to a machin shop explain what you want to do they usualy have good ingeniors in house