Notches That Fit First Time: Our Free Tube Coping Calculator
Anyone who's built a roll cage, chassis or bull bar knows the routine: grind a notch, test fit, see the gap, grind again. Take off too much and the tube is now too short. The CDI Tube Coping Calculator takes the guesswork out of it. It's free and you don't need to sign up.
What it does
Enter your main tube OD, branch tube OD and wall thickness, then set the joint angle, any offset from centreline and a notch allowance if you want one. The calculator shows a preview of the joint and generates a wrap-around template printed at 1:1. The template shows the outer cut line and the inner wall edge.
Print it, check the 50 mm calibration bar measures correctly, line the top edge up with a square-cut end of the tube, wrap it around, mark the line and cut.
Why it matters for businesses
- Less rework: a notch that fits first go means less time at the grinder and no re-cut tubes.
- Predictable labour: when fit-up is repeatable, it's easier to quote cage and chassis work accurately.
- Consistent quality: tight, even fit-up makes joints easier to weld cleanly, whoever is doing the prep.
- Less scrapped material: fewer over-cut tubes that end up in the bin.
Why it matters for DIY builders
- No notcher needed: mark the cope from the template and cut it with a grinder, bandsaw or file.
- Handles awkward joints: different tube sizes, any angle, and offset joints that don't meet dead centre.
- More confidence: you can see the profile before you cut, instead of learning by ruining tube.
What can you use it for?
Roll cages, chassis and space frames, bull bars and rear bars, roof racks, trailers, handrails, furniture and any other tube-to-tube joint.
Try it now
Open the free Tube Coping Calculator.
Planning your tube order too? Our Linear Cut Calculator works out how many lengths you need, and the Sheet Cut Calculator handles your panels.