Welding Tips and Tricks

Almost always end up with cuts off anlge and when puting together, gaps are to big to weld them.I draw a peace on welding table and try to match peaces to the drawing, but still end up with cuts of anlge, specially on profiled pipes.This really gives me a headache I use metal chop saw and angle grider, I know it's not the best choice, but I don't have a band saw yet.Greatfull for any advice to get those cuts right, as I am still pretty new to welding.

check the cut off saw, it may need re aligning.
the other thing is pressing to hard and distorting the blade when cutting.

it must be way out to not be able to weld a gap.
what welding process?

Abrasive chop saws are not accurate for angles, too much sideways flex in the blade. You have to live with it, or upgrade to a different type of saw. Steel blade tungsten tip, band saw or a steel blade with coolant. The first two beings the cheapest option for the home gamers.

For cutting profiled pipe, a tubing notcher is easy enough to build, cheap enough to buy. Decent bi-metal holes mounted onto an electric drill make short, clean work and produce very accurate cuts. You will always need a slight bit of cleanup afterwards, so a flap disc on your grinder works a treat.

+1 on switching from the abrasive disc. Steel cutting circular blade is the way to go.

Like he said. It’s really hard to get repeatable accurate results. Swag off-road makes a slick table for a portaband saw. Then the dry cut saw as far as price goes. Then a fuller sized horizontal bandsaw. And you do get what you pay for on quality.

This is what we call a cold saw in Australia. It's a hss blade that runs at a slower rpm with lots of coolant. They are the staple of most engineering workshops, at least before bandsaws became common. Much smaller footprint than a bandsaw though.

keep in mind abrasive chop saws work well enough. tho most are 90 degree cuts only.
even a rough cut is close enough to be welded. i know workshops where thats all they use. no problems with welding anything.

problems can arise when trying to free hand miters with saw or grinder.

if your doing say tidy tig welding where you need good tight fit, then you need to have accurate miter cut saws.

Look at these saws they are like a cold saw but do not use coolant. At 300 to 400 bucks it is my main metal cutting saw.