fabrication help?

I wonder if anyone has made a joint like this, i'm using a cutoff wheel is there a better way?

 

Might I ask what the application is? If it were me, I would just keep going with the cutoff wheel.

 

@Mobtown Offroad a little fab maybe for this guy.

 

Plasma cutter! But theyre expensive.

Portable band saw, cheaper, clean cut.

Right angle grinder with a cut off wheel, slow, cheap and probably the most dangerous. Wear a face shield.

 

Use a drill bit or hole saw close to the radius of the tube corner then cut into that with your angle grinder.

 

Best advice so far. You want a generous radius in the corner, to reduce the stress concentration. The straight cuts can be made with an angle grinder or better yet, a bandsaw.

 

Hold one tube on top of the other, draw a line with a sharpie to trace around the tube. Then use angle grinder to cut V into tube close but not all the way to the line. Then swap the cutting disc for a flap disk and grind to the line, that will let you make a curve. Easiest and cheapest with the tools you have showing

 

I am a dope, yes, this. We typically drill a hole in the corner the radius of the part fitting to. I misunderstood.

 

@tostada I'm still curious what you are fabbing, that's some heavy wall material ya got.

 

OA or plasma cut it is best. I'd find a buddy with a torch and cut that puppy in 10 seconds flat, kiss it with a wheel to clean it / little bevel and you'll be rocking and rolling

 

Thanks, all!
going to be rock sliders. The material in photo is just what I have lying around.
Will use .188 or .120 wall. Hoping to make the outer rail on diagonal because I've never seen them that way.
This baby is in the mail

 

Yep. That'll slice 1/8" no prob. Like these guys said. Just use a drip bit to pop a hole in your deep corner and work towards it.

Using square or round tubing?

 

If you use the sliders as a step, having the pointy end up isn't comfortable on your sole.

I was thinking more of a vertical bandsaw like this one. So you can slide the tube to the blade at a 45 deg angle:

 

swag offroad makes this to fit nearly any porta band I think I can make my own

 

http://www.swagoffroad.com/Metal-Fabrication-Tools-_c_7.html

 

The "stationary" vertical bandsaws typically have an adjustable blade guide that you can lower to limit blade flex, very helpful for making contour cuts.

 

It’s a good idea, it’s just a lot more of a pain to build then that way. Great for a one off custom set. Not great for production runs.

 

frankensaw

 

^Do you need to keep constant pressure on the switch or is it latched?

 

have to rig something, trigger doesn't lock.
It does however have variable speed dial