Joining the end of one piece of tubing to another is known as notching, or coping, the tube. It’s all based on angles that are determined by where you are placing the tube. Notches range from a true 90-degree cope (forming a T joint) and on down from there. Note that copes where the small angle is less than about 20 degrees are slightly awkward since the two pieces of tubing approach parallel. There are several ways to notch tubing, and if you want to do much fabrication, you’d better get good at doing one, if not all, of them.
Here are some tips and methods we usually use to add a notch, or cope, to steel structural tubing when we build rollcages, bumpers, shock towers, frame crossmembers, roof racks,…