How to Cope Pipe (With Printable Templates)

Coping (also called "notching") is one of the most important skills in metal fabrication—especially when building roll cages, handrails, chassis parts, or tubular frames. A perfect cope gives you tight joints, cleaner welds, and a stronger finished structure.

Today you don't need complicated math or expensive tools… You can print a pipe coping template, wrap it around the tube, mark the cut, and notch perfectly every time.

Why Coping Matters

When two round tubes join, they must fit together with minimal gaps. A good cope:

• Increases weld strength
• Reduces filler wire use
• Reduces grinding cleanup
• Helps with precise angles and geometry in complex builds

Whether you're fabricating a roll cage or building a metal project in your garage, a coping template makes the process fast and accurate.

Tools You Can Use to Cope Pipe

You can cope pipe using a variety of tools depending on your budget and precision needs:

1. Angle Grinder

• Most common
• Good for field work
• Great with Coping / Notching Templates
• Low Budget: $50+

2. Hole Saw Notcher

• Quick and repeatable
• Works with drill press or handheld drill
• Good for 90° and angled cuts
• Medium Budget: $800+

3. Plasma Cutter or CNC Tube Cutter

• Fast
• Perfect for Production Shops
• Requires careful touch-up
• High Budget: $2000+

How to Use a Printable Coping Template

Here's the simple step-by-step method:

Step 1 — Enter Your Tube Size

In the FabToolkit coping generator, enter:

• Outside diameter (ex: 1.75")
• Wall thickness (ex: 0.125")
• Intersection angle (ex: 45°, 90°, etc.)

Step 2 — Print the Template

• Print the PDF at 100% scale (no fit-to-page).
• The template includes 2 cut lines that wrap perfectly around the tube. One is the thickness compensated cut line, which is the simplest cut. The outer line may be used if thickness feathering is desired.

Step 3 — Wrap the Template Around the Tube

Use:

Tape(Scotch or Masking) and a Permanent Marker(Black or Silver) or Wax Pencil

Make sure the template aligns smoothly with no wrinkles.

Step 4 — Mark Your Cut

Trace the line directly onto the tube.

Step 5 — Cut and Fine-Tune

Use your angle grinder, band saw, or desired tool to follow the line.

Finish with:

• Belt sander
• Flap disk
• Grinder wheel

The tube should fit perfectly against the mating tube with almost zero gap.

Tips for Perfect Coping

• Double Check your pipe OD and thickness before printing your template
• Check your branch pipe clocking before marking your cut line
• Always cut outside the line and grind to fit
• Use a vise to hold tubing securely

Final Thoughts

Coping doesn't have to be difficult. With printable templates, you can get accurate, repeatable results without specialized tools. This method works for:

• Roll cages
• Chassis bracing
• Bike frames
• Furniture
• Fabrication art
• Handrails
• Off-road bumpers