How to make this notch?

Xtreme Cartz · 11-29-2009, 04:42 PM

I'm making a safari roof rack, rear cargo bed, and a clays basket for my blue EZGO, and I wanted some gussets added to the roll cage while I was in there. I can't believe how difficult it is to notch that simple looking gusset. I'm able to get the notch on the vert tube fitting pretty good, but the horizontal is a messin with me big time! 12th attempt I still dont have the gap filled. What's the secret for this?

I kind of see what it needs to do but I can't get it right by hand or with the tubing notcher. In the pics it looks like you could just rotate the notch some, but that isnt working in reality.

2nd question: In the 3rd pic you see the horizontal tube is set back further than the vert. Is this type of joint location referred to as off set? Thank you!

DOOmsman · 11-29-2009, 06:58 PM

Is it that you have to rotate that notch off of paralel from the plumb notch on the vertical tube?

kellys~hotrods · 11-29-2009, 07:16 PM

I would use a tubing notcher, one can be had from Harbor Freight for under $50. Here is a link:

http://www.harborfreight.com/cpi/cta...112&zmap=42324

You can spend a bit more money for a nicer one, but if you are only using it a couple times or for one project I would go with the inexpensive unit. I may pick one of these up myself for my cart to fab the safety cage and possibly shock hoops.

Kelly

*edit* I saw you have a notcher, I think those angles require a notch to be cut at different angles from 2 sides. It looks this way in the last pic you posted. I seem to remember seing this done on Extreme 4X4 before, but they have the benefit of some very cool software and a Tube Shark.

scottyb · 11-29-2009, 08:39 PM

I would weld that bitch

mikesmotortoys · 11-29-2009, 08:52 PM

That's the tricky stuff right there

I use my eye and a portable grinder (patience is also a plus). I'm going to get a nice tubing notcher some day, myself

OK - How would I do this? Make your gussets out of 1/2" tube! They look just as good, serve the same purpose and they are MUCH easier to make fit

jmz · 11-29-2009, 11:21 PM

I was building something out of pipe back in the late 80`s or early 90`s. I was having a hard time getting it notched out right. I asked a co-worker when I got to work the next day how to do it. He said ( it`s easy John Mark, cut it , if it don`t fit , cut it a little MO )

I would also just weld it up

I would also grind a little on the other end so I could rotate enough to split the difference before I welded it.

Fleck · 11-29-2009, 11:34 PM

Quote:

Originally Posted by scottyb

I would weld that bitch

Xtreme Cartz · 11-30-2009, 12:31 AM

Hey thanks guys!

Dooms, thats what I thought but for some reason everytime I rotate the notch it leaves the other side off.

Kelly, I have two of those tube notchers and they do work great after some adjustment to the clamps with small washers. The only problem is they have two bronze bushings that start to wear out. I wonder if these could be replaced with new ones from a hardware store? Xtreme 4x4 is one of my favorite shows...I didn't know it was still on. Maybe I need to start waking up earlier on Saturdays.

Scotty, Scotty.

The gap looks nicer in the pics. There's actually about 1/4" to 1/2" on either side.

Mike, ahh yes that is very smart! I'll give it a try with some smaller tubing. I never could have imagined that gusset would be this tricky...they make it look so easy in the movies.

Thanks for the advice jmz.

DOOmsman · 11-30-2009, 10:12 AM

It is hard to do, you have to start the pilot bit at an angle on the slope. Then replace the pilot bit with a pin so as not to wander with the side load on the cutting cup.

ApexVintage · 12-01-2009, 11:57 PM

Cut a piece of stiff manilla folder and wrap it around the tube and tape it together. slide it up to where you want the notch to be and keep cutting it until you have a template that you can mark and index to the new piece of tubing. It looks like you know what the angles are supposed to be, you just need to get the axis in the right place. I always save pieces I've screwed up. If I have something with complex bends in it I can cut and scab together these pieces to get everything to fit right, then duplicate everything on a new piece of tube. Hope this helps.

Dave

11-29-2009, 06:58 PM	#2
DOOmsman Gone Wild Join Date: Jul 2008 Location: Reddick IL Posts: 11,220	Re: How to make this notch? Is it that you have to rotate that notch off of paralel from the plumb notch on the vertical tube?

11-29-2009, 07:16 PM	#3
kellys~hotrods Gone to refill cooler... Join Date: Nov 2009 Location: Sacramento, California Posts: 1,445	Re: How to make this notch? I would use a tubing notcher, one can be had from Harbor Freight for under $50. Here is a link: http://www.harborfreight.com/cpi/cta...112&zmap=42324 You can spend a bit more money for a nicer one, but if you are only using it a couple times or for one project I would go with the inexpensive unit. I may pick one of these up myself for my cart to fab the safety cage and possibly shock hoops. Kelly edit I saw you have a notcher, I think those angles require a notch to be cut at different angles from 2 sides. It looks this way in the last pic you posted. I seem to remember seing this done on Extreme 4X4 before, but they have the benefit of some very cool software and a Tube Shark.

11-29-2009, 08:39 PM	#4
scottyb Happy Carting Join Date: Dec 2007 Location: Southern California Posts: 73,418	Re: How to make this notch? I would weld that bitch

11-29-2009, 08:52 PM	#5
mikesmotortoys Gone Wild Join Date: Mar 2008 Location: Rockwall, Texas (Dallas / Ft. Worth) Posts: 7,077	Re: How to make this notch? That's the tricky stuff right there I use my eye and a portable grinder (patience is also a plus). I'm going to get a nice tubing notcher some day, myself OK - How would I do this? Make your gussets out of 1/2" tube! They look just as good, serve the same purpose and they are MUCH easier to make fit
	www.MIKESMOTORTOYS.com www.EZGOPARTSONLINE.com Factory EZGO - Bad Boy Buggy - Dixie Chopper Mowers

11-29-2009, 11:21 PM	#6
jmz Gone Wild Join Date: Jul 2009 Location: Gonzales, Texas Posts: 585	Re: How to make this notch? I was building something out of pipe back in the late 80`s or early 90`s. I was having a hard time getting it notched out right. I asked a co-worker when I got to work the next day how to do it. He said ( it`s easy John Mark, cut it , if it don`t fit , cut it a little MO ) I would also just weld it up I would also grind a little on the other end so I could rotate enough to split the difference before I welded it.

Today
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11-30-2009, 12:31 AM	#8
Xtreme Cartz The Fabricator Join Date: Dec 2006 Posts: 2,016	Re: How to make this notch? Hey thanks guys! Dooms, thats what I thought but for some reason everytime I rotate the notch it leaves the other side off. Kelly, I have two of those tube notchers and they do work great after some adjustment to the clamps with small washers. The only problem is they have two bronze bushings that start to wear out. I wonder if these could be replaced with new ones from a hardware store? Xtreme 4x4 is one of my favorite shows...I didn't know it was still on. Maybe I need to start waking up earlier on Saturdays. Scotty, Scotty. The gap looks nicer in the pics. There's actually about 1/4" to 1/2" on either side. Mike, ahh yes that is very smart! I'll give it a try with some smaller tubing. I never could have imagined that gusset would be this tricky...they make it look so easy in the movies. Thanks for the advice jmz.

11-30-2009, 10:12 AM	#9
DOOmsman Gone Wild Join Date: Jul 2008 Location: Reddick IL Posts: 11,220	Re: How to make this notch? It is hard to do, you have to start the pilot bit at an angle on the slope. Then replace the pilot bit with a pin so as not to wander with the side load on the cutting cup.

12-01-2009, 11:57 PM	#10
ApexVintage Not Yet Wild Join Date: Dec 2008 Posts: 69	Re: How to make this notch? Cut a piece of stiff manilla folder and wrap it around the tube and tape it together. slide it up to where you want the notch to be and keep cutting it until you have a template that you can mark and index to the new piece of tubing. It looks like you know what the angles are supposed to be, you just need to get the axis in the right place. I always save pieces I've screwed up. If I have something with complex bends in it I can cut and scab together these pieces to get everything to fit right, then duplicate everything on a new piece of tube. Hope this helps. Dave
ApexVintage Not Yet Wild Join Date: Dec 2008 Posts: 69

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