Ideal way to notch tube
 

Getting ready to build the 6 point cage for my nova, resembling the green sleeper nova cage. The goal is to have it as hidden as possible. Anyways, when building our baja chassis out of chromoly at school we used a baileigh tn250 notcher (which I wasn't too impressed with) as well as a combination of hand grinding/filing them. Now that I'm home, I have a bridgeport that I can use, but I'm not sure if that is the ideal way. I was just curious how everyone fits their notches if they're using a notcher, mill, or whatever.

I'm curious, what was it you didn't like about the Baleigh? I created of list of tools to buy throughout the future and after researching it seemed like most liked the Baleigh the best.

I've used a few and I like the Rogue fabrication notcher best. I actually prefer that or coping temples and a cut off wheel/ flap disc.

I don't do enough tube to justify a notcher but I do have a bridgeport. That and a roughing end mill makes quick work of it.

https://cdn.mscdirect.com/global/ima...0188796-23.jpg

I've notched tube for years with a notcher, mill, etc... Saw a video a few years back and tried his method. Waaaay faster and easier. Its the only way I do it anymore.

https://youtu.be/mHBanmfn_CA

The way it grabbed the pipe was nice since it was always centered, but when we used thin wall pipe for parts of our chassis(.035, .045, and even .065) it wouldn't grab on too well and either dent the pipe or it would slip.

Yeah I've used a normal end mill before but it definitely didn't like it, will have to give that a try.

Definitely better than using a cutoff wheel and grinder only, I'm surprised that's better than a notcher or mill though, I'll have to give it a shot. I found this link in a comment on that video which I like a lot too.

http://metalgeek.com/static/cope.pcgi

That's the coping method I was talking about.

http://metalgeek.com/static/cope.pcgi

That is GREAT but expensive. we use Hole saws in the bridgeport on a mandrel that we make so they are more stable. at 7.00 they will cut ALOT of tubes. and then you throw them out.
We have a standard tube notcher that we use for R&d or one off cuts but for production we use the hole saws