I need to cut a notch in the end of sched 40 3.5 inch pipe to allow 2 inch
pipe to pass through it. Available tools are reciprocating saw, drill press
with bits up to 1 inch and bimetal hole saws, and cutting torch. What's
the best way to do it? The notch needs to be snug because the 2 inch pipe
will be welded to the 3.5 inch pipe using stick welding.

Mike

Note: To email me, use the address below with the q's removed:

I need to cut a notch in the end of sched 40 3.5 inch pipe to allow 2 inch
pipe to pass through it. Available tools are reciprocating saw, drill
press
with bits up to 1 inch and bimetal hole saws, and cutting torch. What's
the best way to do it? The notch needs to be snug because the 2 inch pipe
will be welded to the 3.5 inch pipe using stick welding.

Single hole or a few? Hole saw and some frustration getting the "plug" out
of the unit. Use a sturdy drill press or milling machine to hold the pipe
and drive the hole saw.

Many holes? Check out Hougen's holesaw-like tools. They automatically
eject the plug so you can go on and on...

I can fax you a page from their catalog if you eMail me privately with a
contact number, etc.

Regards,
Joe Agro, Jr.
(800) 871-5022
http://www.AutoDrill.com
http://www.Multi-Drill.com

V8013

newsman wrote:
I need to cut a notch in the end of sched 40 3.5 inch pipe to allow 2 inch
pipe to pass through it. Available tools are reciprocating saw, drill press
with bits up to 1 inch and bimetal hole saws, and cutting torch. What's
the best way to do it? The notch needs to be snug because the 2 inch pipe
will be welded to the 3.5 inch pipe using stick welding.

Are you going to pass the 2" pipe at right angles to the 3.5" pipe? If
so, cut a pair of 2" holes opposite each other in the big pipe, then
whack off the end (if you really want something called a "notch"). This
will waste a bit of your big pipe, but not much and it'll be a nice notch.

--

Tim Wescott
Wescott Design Services
http://www.wescottdesign.com

newsman wrote:
I need to cut a notch in the end of sched 40 3.5 inch pipe to allow 2 inch
pipe to pass through it. Available tools are reciprocating saw, drill press
with bits up to 1 inch and bimetal hole saws, and cutting torch. What's
the best way to do it? The notch needs to be snug because the 2 inch pipe
will be welded to the 3.5 inch pipe using stick welding.

If you've got a good bimetal hole saw, and your drill press will run at
the appropriate speed, and you can clamp everything down solidly, then
that's the way to go.

"newsman" wrote in message
...
I need to cut a notch in the end of sched 40 3.5 inch pipe to allow 2
inch
pipe to pass through it. Available tools are reciprocating saw, drill
press
with bits up to 1 inch and bimetal hole saws, and cutting torch.
What's
the best way to do it? The notch needs to be snug because the 2 inch
pipe
will be welded to the 3.5 inch pipe using stick welding.

Mike

Note: To email me, use the address below with the q's removed:


Since you are going to weld a pipe back in, I'd use the cutting torch.
If your good with the torch the somewhat jagged hole will be welded up.
Much less effort than trying to secure in a drill press. Also you didn't
mention how long the 3.5" pipe is. Might be tough to wrestle into
position on a drill press.

Regards,
Bernd

Bernd wrote:
"newsman" wrote in message
...

I need to cut a notch in the end of sched 40 3.5 inch pipe to allow 2
inch
pipe to pass through it. Available tools are reciprocating saw, drill
press
with bits up to 1 inch and bimetal hole saws, and cutting torch.
What's
the best way to do it? The notch needs to be snug because the 2 inch
pipe
will be welded to the 3.5 inch pipe using stick welding.

Mike

Note: To email me, use the address below with the q's removed:



Since you are going to weld a pipe back in, I'd use the cutting torch.
If your good with the torch the somewhat jagged hole will be welded up.
Much less effort than trying to secure in a drill press. Also you didn't
mention how long the 3.5" pipe is. Might be tough to wrestle into
position on a drill press.

Regards,
Bernd



I'd like to see him cut that hole with the stick welder G
Gas torch wasn't in the list of available tools.

--
- -
Rex Burkheimer
WM Automotive
Fort Worth TX

Been there, done that, result is UGLY but it does work. Dampen the rod
first.

Rex B wrote:


Bernd wrote:

"newsman" wrote in message
...

I need to cut a notch in the end of sched 40 3.5 inch pipe to allow 2
inch
pipe to pass through it. Available tools are reciprocating saw,
drill press
with bits up to 1 inch and bimetal hole saws, and cutting torch. What's
the best way to do it? The notch needs to be snug because the 2 inch
pipe
will be welded to the 3.5 inch pipe using stick welding.

Mike

Note: To email me, use the address below with the q's removed:




Since you are going to weld a pipe back in, I'd use the cutting torch.
If your good with the torch the somewhat jagged hole will be welded
up. Much less effort than trying to secure in a drill press. Also you
didn't mention how long the 3.5" pipe is. Might be tough to wrestle
into position on a drill press.

Regards,
Bernd


I'd like to see him cut that hole with the stick welder G
Gas torch wasn't in the list of available tools.

Rex B wrote:

Bernd wrote:
"newsman" wrote in message
...

I need to cut a notch in the end of sched 40 3.5 inch pipe to allow 2
inch
pipe to pass through it. Available tools are reciprocating saw, drill
press
with bits up to 1 inch and bimetal hole saws, and cutting torch.
What's
the best way to do it? The notch needs to be snug because the 2 inch
pipe
will be welded to the 3.5 inch pipe using stick welding.

Mike

Note: To email me, use the address below with the q's removed:



Since you are going to weld a pipe back in, I'd use the cutting torch.
If your good with the torch the somewhat jagged hole will be welded up.
Much less effort than trying to secure in a drill press. Also you didn't
mention how long the 3.5" pipe is. Might be tough to wrestle into
position on a drill press.

Regards,
Bernd



I'd like to see him cut that hole with the stick welder G
Gas torch wasn't in the list of available tools.

--
- -
Rex Burkheimer
WM Automotive
Fort Worth TX

Geez Rex, Drink more coffee or sumthin'.

You even quoted his tools list in your post. Refer back to the bit that
says "cutting torch" just a couple dozen letters past the bit that says
"available tools" :-)

Cheers
Trevor Jones

newsman wrote:

I need to cut a notch in the end of sched 40 3.5 inch pipe to allow 2 inch
pipe to pass through it. Available tools are reciprocating saw, drill press
with bits up to 1 inch and bimetal hole saws, and cutting torch. What's
the best way to do it? The notch needs to be snug because the 2 inch pipe
will be welded to the 3.5 inch pipe using stick welding.

Mike

Note: To email me, use the address below with the q's removed:



Why not buy a T - that mates the 3.5 to a 3.5 and the cross is 2" to 2".

Martin

--
Martin Eastburn, Barbara Eastburn
@ home at Lion's Lair with our computer
NRA LOH, NRA Life
NRA Second Amendment Task Force Charter Founder

pipe to pass through it. Available tools are reciprocating saw,
drill press
with bits up to 1 inch and bimetal hole saws, and cutting torch.

I'd like to see him cut that hole with the stick welder G
Gas torch wasn't in the list of available tools.

Rex,

Reread the OP's post. I think you'll find he said he has a cutting
torch.

Bernd

Rex B wrote:


Bernd wrote:
"newsman" wrote in message
...

I need to cut a notch in the end of sched 40 3.5 inch pipe to allow 2
inch
pipe to pass through it. Available tools are reciprocating saw, drill
press
with bits up to 1 inch and bimetal hole saws, and cutting torch.
What's
the best way to do it? The notch needs to be snug because the 2 inch
pipe
will be welded to the 3.5 inch pipe using stick welding.

Mike

Note: To email me, use the address below with the q's removed:



Since you are going to weld a pipe back in, I'd use the cutting torch.
If your good with the torch the somewhat jagged hole will be welded up.
Much less effort than trying to secure in a drill press. Also you didn't
mention how long the 3.5" pipe is. Might be tough to wrestle into
position on a drill press.

I'd like to see him cut that hole with the stick welder G
Gas torch wasn't in the list of available tools.

Pass me the carbon rods, and stand well back.