PieCut – pie cut template for segmented exhaust bends
Make a 90° exhaust bend from straight tube, without a tube bender. PieCut holds the tube on your band saw at the right angle and the right length, so every piece comes out the same. You don’t need to be a professional welder: if you can use a band saw and a marker, you can make a clean pie cut bend.
What is a pie cut bend?
A pie cut bend (also called a segmented or lobster bend) is made from short pieces of straight tube. Each piece is cut at an angle at both ends – these pieces are called segments. Weld the segments together and you get a bend. PieCut makes every segment with exactly the same angle and length, so the bend is round and the segments line up.
What’s in the box
- 1 PieCut template for the tube diameter and segment angle you choose
- 2 radius inserts: 1D and 1.5D (for 2D you use the template without an insert)
Ordering the Full set (all 4 angles)? Then you get 4 templates – 10°, 15°, 18° and 22.5° – each with its own 1D and 1.5D inserts.
This is a physical tool, shipped to you. No STL files or digital downloads.
What you need
- Band saw
- Marker
- Straight tube with the same outside diameter as your template – steel, stainless or aluminium, any wall thickness
- A file or deburring tool, and a welder
Step by step
- Mark the tube. Draw two straight lines along the tube, exactly opposite each other – one on top and one underneath (180° apart).
- Choose the radius. Put the 1D or 1.5D insert in the template, or no insert for 2D (see the table below).
- Put the tube in the template. Slide it through the template with one marker line on top, lined up with the notch on top of the template. Push the tube end against the stop (or against the insert).
- Cut. Cut the tube with the band saw through the slot of the template. The first cut only gives the tube end its angle.
- Turn the tube 180°. Now the other marker line is on top. Push the tube against the stop again and cut. You now have your first segment.
- Repeat – turn 180°, push to the stop, cut – until you have all the segments you need.
- Weld. Deburr the segments, line them up using the marker lines, tack weld, check the angle, then weld them all.
Important: stop the saw as soon as the tube is cut through. Feed the saw by hand and stop right away – if the blade keeps going, it cuts into the plastic template and damages it. This is the most common mistake.
Choose the segment angle
All four angles make a 90° bend. More segments = a smoother, rounder bend, but more cuts and more welds.
10° – 9 segments (10 cuts). The smoothest bend, the closest to a mandrel bend. The most work.
15° – 6 segments (7 cuts). A smooth bend with fewer welds. A good balance for most exhaust work.
18° – 5 segments (6 cuts). Quick to make and still a clean look.
22.5° – 4 segments (5 cuts). The fewest cuts and welds – the fastest way to a 90° bend, with the classic segmented look.
Choose the bend radius
D is the outside diameter of your tube. The radius is measured to the centre line of the tube.
| Radius | How | Example: 63.5 mm tube |
|---|---|---|
| 1D – tight bend, for small spaces | 1D insert | R = 63.5 mm |
| 1.5D – the usual exhaust radius | 1.5D insert | R = 95 mm |
| 2D – long, smooth bend | No insert | R = 127 mm |
Specifications
| Material | PETG – tough, durable 3D-printed plastic, solid body |
|---|---|
| Tube outside diameter | 38.1 to 108 mm (choose your size above). Measure your tube with a caliper before ordering. |
| Segment angles | 10°, 15°, 18°, 22.5° |
| Bend radius | 1D, 1.5D, 2D – one template, three radii |
| Cutting tool | Band saw |
| Tube material | Any: steel, stainless, aluminium – any wall thickness |
Save on several angles
- 2nd and 3rd angle in the same diameter: 15% off, applied automatically in the cart
- All 4 angles in the same diameter: pay for 3 – choose “Full set – all 4 angles”
Need another size?
Message me on WhatsApp, Telegram or Instagram and tell me your tube diameter.
Safety
The template is plastic. Use it only with a band saw. Keep it away from sparks, grinders, open flames, welding heat and hot metal. Keep your hands away from the blade and wear eye protection.
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