Doing pie cuts? How?

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Anyone have any good info on how to do pie cuts on a straight pipe to make a bend? I've made a few cuts on a straight pipe but (say it's 1.5" diameter) after the cut it ends up being a lot bigger.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:For such small pipe you would be better to make cuts at an angle such as two 22.5 degrees to make a 45 degree and four cuts at 22.5 to make a segmented 90 degree bend.   On 1.5 diameter you might try heating a wedge to red heat then pulling the pipe until it bends 15 degrees.  Heat another wedge next to the first then pull it to bend another 15 degrees and so on until you get the bend you want.  Wrinkle bending was standard when pipe benders were rare.  Look at figure B-11   http://www.globalsecurity.org/milita...5-482/Appb.htm
Reply:What kind of wedge? It's 6061 so I don't think it will bend easy, I'm sure it will just break.What's a good way to get a 22.5 line on the pipe so I can cut it with a dremel. My chop saw doesn't leave a smooth edge.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:dremel=you will be old before its done. cut and grind? thinwheel on a grinder?
Reply:Buy a bend... if you can't afford one sell the dremel.Welding/Fab Pics: www.UtahWeld.com
Reply:When cutting aluminum treat it like wood and use carbide tooling.  You can cut with a table saw, radial arm saw, chop saw, or skil saw.   Use a carbide toothed blade best if ground for cutting nonferrous alloys.  Slow feed in and watch for jamming.  6000 alloys are a bit gummy so use saw wax or some people spray alcohol solution on cut.  I do a lot of this type of cutting using a 7 1/4 inch carbide blade on a skill saw.  I try for a blade with more than 30 teeth but I don't spend the extra for an alloy cutting blade.
Reply:in for more info on how to do this for the 'hobbyist' - Any pictures of DIY?Hobart Handler 125 #500495Miller Diversion 165 #907005 (tig learning box)
Reply:You wanna do something like this? http://weldingdata.com/pipetemplatesample.htmUA local 32Team weld-coolTeam miller elite tack upMiller pro-staff
Reply:Originally Posted by lotechmanWhen cutting aluminum treat it like wood and use carbide tooling.  You can cut with a table saw, radial arm saw, chop saw, or skil saw.   Use a carbide toothed blade best if ground for cutting nonferrous alloys.  Slow feed in and watch for jamming.  6000 alloys are a bit gummy so use saw wax or some people spray alcohol solution on cut.  I do a lot of this type of cutting using a 7 1/4 inch carbide blade on a skill saw.  I try for a blade with more than 30 teeth but I don't spend the extra for an alloy cutting blade.
Reply:I use this Pie Cut Calculator excel sheet. Punch in the specs you need and it'll tell you what angle to cut the wedges at and how long. I made a bunch of these today, had I known this would've come up I would've taken some pictures to help you out. I'll see if I can get some time tomorrow to do that
Reply:http://metalgeek.com/static/cope.pcgi