How to build a jig for this pipe

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My friend has a evoX and I want to make him an upper intercooler pipe. Figured it should be simple enough, 2 45* aluminum pipes and 1 weld. I want to do this to see if my welds can handle his power level. 25psi (ish).  How can I make a jig for this incase i wanted to make another one in the future?It's just the upper portion of the intercooler pipe.Just the red pipe in this pic is what is is.Torchmate 2x2 CNC with Flashcut CNC controlsHypertherm Powermax45 Esab ET220i Razorweld 195 MigRazorweld 200ac/dc TigTormach 770, Tormach xstechRazorweld, Vipercut/Vipermig, SSC Foot Pedal Dealer
Reply:Down and dirty for a limited production is use muffler clamps, the bottom of the clamp (channel section) can be tack welded to scrap tubing to hold the piece in position. Use a piece of channel or tube for a base and space the clamp bottom with whatever scrap is needed.  Use the longest straightest section as a reference plane and take a few pics and there you go, fixture in under an hour for less than 20 bucks. "Anybody can talk $h!t behind a monitor, I let the quality of my work speak for itself"Lincoln Square Wave 255 and 355 Tig Lincoln 255 Power-Mig w/ spool gun Koike 5 x 10 CNC plasma Hyd-Mech DM-10 bandsaw Ineco QB-76 NC tube bender
Reply:I use tubing of the same size, cut lengthwise down the middle.  After it is cut and deburred, you'll need to lay it over the top of same sized material, and smack it down over the tube, so it opens up a bit.  Make sure you support the prototype piece at the ends with these "half shells".  This way, you'll be able to just draw a cut line at each end.  Like Coupebuilder said, support the long, striaght section too, and build the base from tube or channel.Another thing to consider when making the original piece is to take note of the degrees of the bend.  Will make production pieces easier.  You could even make patterns of those angles.  Just lay them over the u-bends you'll use, draw your cut lines, and go for it.-AaronJet 17.5" Drill Press1942 South Bend 16x84 Lathe1980s Miller 320A / BP --- 2013 Power Mig 2562012 Jet 7x12 Horizontal BandsawVictor O/A Setup