How to calculate compound tube angle (ie - winch hoop to flat bumper) - Pirate4x4.Com : 4x4 and Off-Road Forum
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Old 08-03-2012, 03:17 PM   #1 (permalink)
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Question How to calculate compound tube angle (ie - winch hoop to flat bumper)

I'm pissing myself off trying to find the answer to this issue. It's especially frustrating as I took years of math in university... must be all the beer.

I'm also sure this has been answered elsewhere, but I must not be able to figure out what to search for.

I just picked up a bender, and plan on making a winch hoop for my bumper.

There are 2 angles where the winch hoop meets the flat bumper surface:
-The "inner bend" angle when viewed from the front
-The "forward lean" angle when viewed from the side.

Here's a hoop that I like that shows what I mean.

So anyway, because the tube is round, there's gotta be a trig formula to compute the single angle I'll need to cut the tube at with a chop-saw, based on the 2 other angles.

I've found a few techniques, but I want the math dammit! Anyone?!
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Old 08-03-2012, 06:58 PM   #2 (permalink)
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I'm sure I could figure it out, but its friday so I feel like being lazy.

wouldn't it just be easier to bend it, mock it up and then cut/grind it to what you need?
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Old 08-03-2012, 07:15 PM   #3 (permalink)
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You have the two angles to consider, so you're going to set the saw for a 30degree cut on each leg(assuming you bent the hoop bends at 60 degrees...which is common for me).

Then you'd tilt the stock up from flat in the saw vise for your lean angle...10degrees maybe, and make the cut.

I don't do that. I make the 30 degree cuts on the ends, which makes it sit flat on the bumper, and then grind any lean angle.

Why? The already bent tube wraps around the saw and doesn't lend itself to such a setup...and the one end of the tube is a mirror of the other, so it has to be tilted down in the's all possible (depending on your saw)but not practical, IMO.
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