Steps to fabricate a square junction in 40mm copper pipe

1. COPPER JUNCTION FABRICATION
Steps for making a square (85o)
junction in 40 mm copper pipe

2. Marking out
• Be accurate with your measurements
• Mark out 2 points 18mm apart
• Centre punch holes to make drilling easier and
accurate

3. Drilling
• Drill 2 x 13mm holes using the pedestal drill
(avoid hand held drill because of bounce)

4. Cutting out
• Cut the metal between holes using tin snips
• Remove burrs and any sharp edges around cut
using a file

5. Annealing the copper
• Anneal and soften pipe around the cut-out
using oxy acetylene
• Repeat softening process as needed during
forming process because material will slowly
become hardened

6. Fabrication
• Use largest forming tool which fits the hole
• Strike forming tool in
upward direction to
prevent ripples
• Don’t oversize hole

7. Fitting branch to junction
• Fit pipe so that it doesn’t extend into junction
• Place branch at 85o (not 90 o)
• When silver soldering place heat above joint
(solder will only flow where heat is)
• Quick soldering will give a better looking weld
• Do not build up silver solder, avoid blobs and
runs