Tube Coping Calculator

Calculate cutting patterns for tube intersections and pipe joints

Calculate Tube Coping

Diameter of the main tube (the one being joined to)
Diameter of the branch tube (the one being cut/coped)
°
Angle between the tubes (90° for perpendicular)
Distance between tube centerlines (0 for centered intersection)

Coping Results

Printable Template

Coordinate Points

Point X Y

Tube Coping Guide

Common Coping Types

Simple Cope
Simple
Saddle Cope
Saddle
Fishmouth Cope
Fishmouth

Standard Tube Sizes

Nominal Size OD (in) Common Wall Thickness (in)
1/2" 0.840 0.065, 0.083, 0.109
3/4" 1.050 0.065, 0.083, 0.113
1" 1.315 0.065, 0.083, 0.109, 0.133
1-1/4" 1.660 0.065, 0.083, 0.109, 0.140
1-1/2" 1.900 0.065, 0.083, 0.109, 0.145
2" 2.375 0.065, 0.083, 0.109, 0.154

Understanding Tube Coping

Tube coping is the process of cutting one tube to fit against another at various angles. This technique is essential in metalworking, fabrication, and pipefitting to create strong, precise joints for structures like railings, frames, and pipe systems.

Types of Tube Coping

  • Simple Coping: The branch tube is cut to fit against the surface of the main tube. This is the most basic form of coping, used when the branch tube ends at the main tube.
  • Saddle Coping: The branch tube is cut to wrap around the main tube, creating a saddle-like shape. This provides maximum contact area for welding and is commonly used in structural applications.
  • Fishmouth Coping: Both tubes are cut to fit together end-to-end, often at an angle. This is used for creating continuous runs of tubing with angle changes.

Applications of Tube Coping

  • Handrails and Railings: Creating smooth, strong joints in railings for stairs, balconies, and walkways
  • Structural Frameworks: Building frames for vehicles, equipment, and architectural elements
  • Roll Cages: Fabricating safety structures for race cars and off-road vehicles
  • Pipe Systems: Creating branched piping for plumbing, HVAC, and industrial applications
  • Furniture: Crafting metal furniture with clean, professional joints

Cutting Methods

  • Manual Cutting: Using a template and hand tools like a plasma cutter, angle grinder, or tube notcher
  • CNC Cutting: Using computer-controlled plasma or laser cutters for precise, repeatable cuts
  • Hole Saw Method: Using a hole saw at the correct angle for simple copes (limited to certain angles)
  • Tube Notcher: Specialized tool designed specifically for creating coped joints
  • Pipe Fitter's Templates: Pre-made templates for common tube sizes and angles

Factors Affecting Coping

  • Tube Diameters: The relative sizes of the main and branch tubes
  • Wall Thickness: Affects the strength of the joint and cutting approach
  • Intersection Angle: Determines the shape of the cope
  • Offset Distance: How far the centerlines of the tubes are from each other
  • Material: Different metals may require different cutting techniques

Steps for Successful Tube Coping

  1. Measure and Mark: Accurately measure and mark the tubes for cutting
  2. Create or Print Template: Use our calculator to generate a precise template
  3. Transfer Pattern: Wrap the template around the tube and transfer the cutting line
  4. Cut Carefully: Follow the marked line with your chosen cutting tool
  5. Deburr and Clean: Remove any burrs or rough edges from the cut
  6. Test Fit: Check that the tubes fit together properly before welding
  7. Weld or Join: Secure the joint using the appropriate welding or joining method
  8. Finish: Grind, sand, and finish the joint as needed

Tips for Better Results

  • Always measure twice and cut once to avoid wasting material
  • Use a fine-tipped marker for more precise marking
  • Consider cutting slightly outside the line and then grinding to the exact shape
  • For critical applications, make a test piece first using scrap material
  • Account for material thickness when planning your cuts
  • Keep your cutting tools sharp and in good condition
  • Use clamps or fixtures to hold the tube steady while cutting
  • For complex angles, consider making a jig to hold the tube at the correct angle
  • Allow for weld shrinkage in critical dimensions
  • Consider the structural implications of removing material from the tube

Safety Considerations

Tube coping involves cutting metal, which can be hazardous. Always:

  • Wear appropriate personal protective equipment (safety glasses, gloves, etc.)
  • Ensure proper ventilation when cutting or welding
  • Secure workpieces properly before cutting
  • Follow all safety guidelines for your cutting and welding equipment
  • Be aware of fire hazards from sparks and hot metal