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BuyTube Notch Template Generator Calculator
Printable wrap-around coping templates for round tube T-joints and angled joints
Enter the OD of the tube being cut, the run tube it saddles onto, and the joint angle. The tool unrolls an exact cylinder–cylinder intersection into a wrap-around strip you can print at actual scale, tape, and trace — no dedicated notcher required for one-offs.
How to use: Cut the tube end roughly square. Download and print the PDF at 100% scale (no “fit to page”) and confirm the 1 in / 50 mm check square with a ruler. Cut out the strip, wrap it around the tube with the straight edge held at a constant line around the circumference, tape it, trace the curved cut line, then grind or saw to the line. Test-fit and adjust. Reference tool — always verify fit on scrap.
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Recommended Measurement & Cutting Tools
Measure OD and joint angle accurately, then grind or cut the cope — products from the TestTalkHQ affiliate catalog
Starrett Electronic Slide Caliper 0–6 in
- 0.0005 in resolution for OD checks
- Confirm tube diameter before printing
- Carbide-tipped jaws hold calibration
- Essential for wrap-template accuracy
Klein Tools 935DGGP Digital Angle Gauge
- Magnetic base for fixture angles
- Match real joint angle to tool input
- Avoids wrong-angle templates
- Shop-floor readable display
Mitutoyo 103-177 Outside Micrometer 0–1"
- Confirm OD when calipers disagree
- Critical on thin-wall tubing
- Trusted shop standard
- Pairs with template print checks
DEWALT 4.5 in Angle Grinder
- Grind to the traced cut line
- Cleanup after bandsaw roughing
- Compact for tube cope work
- Shop staple for one-off notches
Intra-FIT Cowhide MIG Welding Gloves
- Hand protection while grinding
- Long cuff for tack welding
- Heat-resistant cowhide
- Useful for fit-up and tacking
As an Amazon Associate, TestTalkHQ earns from qualifying purchases. Catalog gap: no dedicated tube notcher or tube fixturing/jig products in the affiliate CSV at publish time.
Exact Cylinder Intersection — Not a Sine Wave Shortcut
Many free coping calculators approximate the cut-back profile as a simple sine wave. That shortcut is only accurate when the branch is much smaller than the run. This calculator solves the true cylinder–cylinder intersection for centered, coplanar axes, so equal-diameter 90° joints get a full-depth fishmouth (depth equals radius) and angled joints stay geometrically correct. See the Tube Notch Guide for the step-by-step print and wrap workflow.
Print Scale Is Non-Negotiable
An actual-scale template is useless if the printer “fits to page.” Every PDF page includes a labeled 1 in / 50 mm reference square — measure it with a ruler before you cut metal. Larger diameters tile across multiple landscape letter pages with an overlap seam so you can tape strips together. If something still does not wrap true, start with Tube Notch Troubleshooting.
When a Printed Template Is the Right Tool
Printed templates shine for one-offs, prototypes, and shops that already own a grinder or bandsaw. High-volume production usually wants a dedicated tube notcher, hole-saw fixture, or CNC tube laser. Compare methods in Template vs Hole Saw vs Notcher. For bend geometry after you notch, use the Tube Bending Calculator and Tube Bending Guide.