Dual-Radius Elbow Cutting Jig

A cutting fixture for mandrel bend elbows, indexed on both radii. Cutting a bought elbow to length by eye is where a clean exhaust goes wrong — the cut walks around the bend and the tangent is off, so the next piece never sits flat. This one references the bend itself.

You can buy a printed fixture, or you can own the file. Printed jigs are good parts — but they are parts. One size, shipped to you, and when it cracks you order another. This is a file. Print that size as many times as you need, forever, on the machine already in your shop, and print the next size at 11pm the night before a deadline.

What you download

• STL file for the size you choose — or the Bulk Pack with all 14 sizes
• Dual radius geometry with an offset blade relief for a true tangent cut
• Instant download at checkout. Nothing ships.

Sizes

1.50" (38.1mm) · 1.65" (41.9mm) · 1.75" (44.5mm) · 1.88" (47.8mm) · 2.00" (50.8mm) · 2.15" (54.6mm) · 2.25" (57.2mm) · 2.50" (63.5mm) · 2.75" (69.9mm) · 3.00" (76.2mm) · 3.50" (88.9mm) · 4.00" (101.6mm) · 4.50" (114.3mm) · 5.00" (127mm)

Print settings

My official settings for every G1Pro fixture: 2.5 mm walls, 2.5 mm top and bottom, 20% cubic infill, support-free, printed in Inland PETG-CF. Print one size and check it against your elbow before committing a spool.

Licence — Shop Use

Print as many copies as you like for use in your own shop, including on paying customer jobs. You may not share or resell the file, or print copies of the jig to sell. Print-and-sell licences available — ask.

Drawn by James Goertz, G1Pro. Building intake manifolds by hand since 2009; these are the fixtures off my own bench.