Is there an easier way?

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So I'm doing a side job building 8 jigs for cow Hoove trimming school. I'm going off the design of what customer brought and wants. My question is I have 16 pieces of angle that I have to notch to fit a 4" OD pipe so this jig can be bolted to a table. Is there an easier way?
Reply:Plasma or oxy fuel torch? What cutting options do you have?Lincoln Precision Tig 185Lincoln Power Mig 256Hypertherm PM 45Everlast 140STSmith O/A
Reply:Do you have a torch? Plasma?  If so I would cut the angle, then grind them smooth.
Reply:No plasma yet. Oxy rig bone dry of course. The method I'm doing isn't horiable and about to go back in shop and finish. For feature or learning another way can be beneficial.
Reply:I would make a cutting jig for using a plasma or torch.
Reply:Originally Posted by oxygen454I would make a cutting jig for using a plasma or torch.
Reply:All they want is to bolt the 4'' pipe to the table ? Does the angle have to be that long ? Why not just weld 4 , 2 x 2 x 1/4 angle clips to the 4'' pipe with holes for bolting ?
Reply:tack them together and holesaw them
Reply:I was going to use flat stock but didn't have enough on hand. Also that's how origanl one is.
Reply:With the tools available i think you made the best choice, personally i would stack them in pairs for the cuts and grinding
Reply:I would have used 4 small tabs With holes in them.
Reply:It went fairly smooth. The thought of grinding so many was overwhelming. Then i remembered all the holes I'll have to lay out and drill! Lol when will i get some hood time and get to weld these up? All in good prep to make nice looking welds!
Reply:GavoHere are two alternatives. The first is 3 pc. flat bar - and the other, angle iron.Both utilize Square Cut components - SC joints are: simple, quick, and can be made with a wide variety of standard shop power tools.Opus Attached Images
Reply:Upright bandsaw.An optimist is usually wrong, and when the unexpected happens is unprepared. A pessimist is usually right, when wrong, is delighted, and well prepared.
Reply:That's why I posted this thread somthing this simple went over my head. I'll post a finished product photo when I start gluing the parts together. They'll look good with the way I cut them. Originally Posted by OPUS FERROGavoHere are two alternatives. The first is 3 pc. flat bar - and the other, angle iron.Both utilize Square Cut components - SC joints are: simple, quick, and can be made with a wide variety of standard shop power tools.Opus
Reply:Considering the tools that you are using to do the job, your radius looks pretty nice. Now go get them tanks filled!  Or do it the way Opus recommended..  -Niche
Reply:I went to trimming school about 10 years ago. All we had was a few bar clamps to hold the cadaver legs to the table. They didn't hold very well and allowed the hoof to move around so much you had to hold it still. As it turned out, live animals move their legs even more when you're trimming them. I'm assuming you are building fixtures to hold the feet for training. There are other designs (like Opus) that are simpler, but are not what the trimming school asked for. I think you're stuck with a lot of grinder work. I hope you have some extra belts for that grinder!Lincoln Precision Tig 185Lincoln Power Mig 256Hypertherm PM 45Everlast 140STSmith O/A
Reply:One 40 grit belt with life still on it and it's part of invoice. They went fast took a few minutes with disk then about a minute or two to grind on belt sander. he's teaching the anatomy of the foot and the profile of the hoof the proper way it needs to be trimmed he does a lot of farms and a few are show cattle. So I think while they learn a station foot would be best. Then when he takes out to start learning on the job. Kind of like welding school teach how to turn on a machine run simple coupons then when you hit the concrete you realize that things are much different to weld in real world conditions. The idea is to get you familiar then continue to learn.
Reply:GavoKudos for gutting-thru the fitting process . . .The two 'alternatives' are age-old standard/structural joint configurations.The pieces are: the easiest to make [no forming], weld [simple fillets], and the weldment is structurally superior. Your configuration/joint is a first-choice - when aesthetics are mandated.Your forming effort should be reserved for 'TIG projects' that pay 2x to 4x the compensation you are receiving.Opus
Reply:Beautiful Fit Up!!!!!.Everlast PowerPro 256, Everlast W300 Cooler, Everlast Cart 250Millermatic 211, Spoolgun 100, Miller HD CartJackson W60 Truesight Digital Auto Darkening, Victor 315 Torch sitting on a Harper 830-86 cart
Reply:Looks good. As stated earlier a hole saw might work. I have had good luck with them. Put in a drill press slow speed and steady pressure.Last edited by Weld one; 02-09-2015 at 09:47 PM.Reason: Spelling
Reply:I really don't like hole saws mainly bc I had to drill many in stainlees pipe as a pipe hand by hand. We would always use a saw a bit smaller bc they always had a bit of wable to them. Drill press would tighten that up much but I think this was the best route. I learned something out of this post and was the intention. Much appreciated.