2.51" OD Pipe welded at 45 Degrees onto a 2.90" OD Pipe.
I had a Pipe (2.90" OD & 2.52" ID) and wanted to weld another pipe (2.52 OD & 2.27 ID) onto it at 45 degrees.
Could have used a pipe wrap or other items but decided to 3D-Print an ABS Plastic 'Scribe Guide'.
When I first tested my 3D-Printer I was shocked how accurate the dimensions of the final items... Since then I have used it constantly for testing part fit-ups before machining the actual parts out of metal.
The 'Scribe Guide' is designed so I know when cut line is drawn on the 2.52" OD pipe the other back end of the plastic guide is exactly 4" from the center line of the larger pipe.
I wanted the smaller 45 degree pipe to be 9" off the center line of the larger pipe ... so I measured an extra 5 inches back from the back end of the 3D-Printed guide and marked it for a straight cut in the horizontal band-saw.
After drawing up the 45 degree 'Scribe Guide' in SolidWorks CAD Software ... then 3D-Printed it.
It took a little over 2 hours to 3D-Print but after pressing the PRINT button I didn't have to watch it or do anything else... I just walked way and worked on another project and came back a few hours later and it was completely done ready to use. (Hands-off means can use time to work on other projects ... or Sleep *grin*)
Many times I will start a 3D-Print and go to bed and wake up in the morning and the 3D-Printed item is finished.
(No Smell or No heat other that protected printing tip when 3D-Printing ... I keep mine in the spare bedroom on a wood dresser)
Use an AFINIA 3D-Printer ~ https://store.afinia.com
Drew on the pipe using a Sharpie marker and cut it will a metal saw but could have used an Oxy/Acet torch, or plasma-cutter ...
The same plastic 'Scribe Guide' can be used to draw on the larger pipe the inner hole cutout area by drawing a line inside the guide with it placed on the larger pipe.
Probably not my best looking weld but decided to weld a little and let it cool and then welded a little more and let it cool... Wanted to keep the longer pipe from warping from too much heat all at once on one side.
The 3D-Printer is very helpful for making unusual shaped parts that don't have a lot of stress on them like the DRO mounts for my new Milling Machine ... This pipe guide also worked very well.