A year or so ago I ran across some excellent software for making templates to cut mitres in tubes. You can use this to join virtually any tube to any other tube at any angle. For example, a merge pipe on a header or a 90 degree joint on a roll cage.

The software is called TubeMiter and is available here:
http://www.ozhpv.org.au/shed/tubemiter.htm

You simply input your tube sizes and wall thicknesses, tell it the angle, and it then shows you a template on the screen. Print the template, cut it out and then wrap it around the tube. Trace the template and then use a cutting instrument of your choice (I use a cutting wheel) to cut it out.

It's a free and easy way to make perfect tubing joints.

 

AWESOME

i needed this months ago, fought with various auto cad plugins which i could never get to work. GREAT resource

 

Sweet ! I'll try this on my wastegate runners this weekend !

Thanks !

 

having trouble downloading this
its downloading as a text document...

 

Great find. Im making a set of headders for a small GM 3.4 (friends car/project that im helping with...) This will make life so much easier. THANKS!!!