How to make a saddle for a pipe at an angle of 90 degrees

Sometimes in summer cottages, garage or home conditions it is necessary to weld two pipes, so that the end part of one fits tightly, without gaps, to the cylindrical generatrix of the other. Only in this case, the connection by welding or soldering will be durable and tight.
In production, such an operation is performed by a mill on a machine.
At home, there is a simple method that allows you to solve this problem with good quality, with a minimum set of equipment.

Training

We will use a cutting wheel mounted cantilever on the shaft of an electric motor or an angle grinder securely mounted on a workbench.
Set the desktop so that its plane is parallel to the axis on which the cutting disc rotates.
Let's shift the working table down in height by half the outer diameter of the processed pipe. By this we achieve the symmetry of the end face processing.

End profile marking

For convenience, we wrap the end of the pipe with white paper masking tape.
On its surface with a black marker or pencil we apply a cut profile.
Ideally, it should correspond to the cylindrical generatrix of the counterpart of the tube.
Absolute marking accuracy is not required. The required profile will be obtained during subsequent processing.

Treatment

We lay the part on the table surface, start the disk engine, and begin to remove excess metal from the end surface, focusing on the markup.
Hold the part tighter, do not let it roll on the table!
Work slowly, remove the metal in several transitions, as carefully as possible.

Fit

Check the resulting profile, attaching it to the generatrix of the second pipe.
The gaps are still large. It does not matter, continue to fit. Gradually, the profile will approach the surface of the second pipe tightly, with minimal gaps.

The finish

The result is very good, the gaps are minimal, now you can weld or solder.
For mass production, the method is not suitable due to the high complexity, but for the needs of personal farming is optimal.
Having gained experience, having trained an eye, having typed a hand, you can learn to process the ends of pipes at connections other than 90 degrees.

Important safety information!

It is desirable that the disk has a protective casing, it is installed initially on angle grinders.
Eyes and face should be protected with glasses, and preferably with a transparent mask. The whole world has long been working in them!
On the hands you need to wear gloves, preferably split. Good luck in job!
Original article in English