How to Make a 90 Degree Pipe Joint Saddle

Use a band saw to make a saddle cut in galvanized or cast iron pipe.

Pipe saddle joints connect two pieces of metal pipe together so they can be welded into place. A simple saddle joint works well for many applications, although some require a more precise cut. A 90 degree angle can be made using two cuts with a band saw, chop saw, or cold cut saw. This method works for joining two pipes that are the same diameter. Pipes of different diameters need different angle cuts.

Things You'll Need

• Band saw
• C-clamp
• Pipe

Instructions

1. Adjust the saw for a 35 degree cut, and clamp the pipe into place in the saw. The cut will not be at the center of the pipe; it will be offset from center about quarter inch.

2. Put a C-clamp on the pipe to act as a stop which will guide you in making the same length of a cut on the opposite side. Make the first cut at a 35 degree angle.

3. Remove the pipe from the saw clamp and turn it 180 degrees, using the C-clamp as a guide to know where to stop turning. Make the second cut opposite the first. This will leave a small flat spot between the cuts rather than a point.

4. Place the pipes together, grinding as needed to adjust them.

Tips & Warnings

• This style of cut becomes easier with practice.

• Immediate discard scrap pieces. They are sharp, and will puncture wheels, shoes and hoses.

References

• IPS Community: BPO116 Simple Saddle Cuts in Pipe

Resources

• Pipe Fitter: Pipe Saddle Layout