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In the photos above, I showed the result of connecting a round pipe with a diameter of 76 mm at 90 degrees. To do this, we made cuts of pipe ends at an angle of 45 degrees with a grinder. The photo shows that the gaps at the joint turned out to be minimal, now I will tell you the sequence of work and this simple way to Using a grinder, cut a round pipe at 45 degrees and connect at 90 .
We have a piece of 76 round pipe. It is important for further marking that its end is cut off at 90 degrees.
First, we divide the pipe circle into 4 even sectors, there is such an article on the channel, you can read it by clicking on this link-an article about pipe division.
After splitting the end of the pipe into 4 parts, we take a piece of the corner, apply it to the pipe and from these 4 points we draw axial lines along the flange of the corner along the pipe a little more than the diameter of our pipe. You don't need to measure anything here, the length of these lines is done just by eye.
On one of the lines, we lay off a segment with a length equal to the diameter of the pipe - 76 mm. We do not put anything on the opposite side, it will be the butt of the cut at 45 degrees.
On the other two lines, we set aside segments half the diameter of the pipe - 38 mm each.
Now we need flexible plastic tape. Disposable clips are good for this purpose, such things bend evenly, and this is what we need.
Using a flexible tape, we combine the points on the 76 mm pipe and two points 38 mm each. Then we markup along this flexible tape. Also from the end of the pipe, we will match the end and two points of 38 mm each.
On the opposite end of the same pipe, I made exactly the same markings.
We take a small grinder on a 125 disc and carefully cut off the excess according to the markings.
We do this from both ends, then we divide the entire pipe in half and cut it into 2 parts. We combine these two pieces with cutouts at 45 degrees and for convenience we tack them by welding at the joint.
The result is a 90-degree connection with minimum gaps in the joint.
Friends, I made a video with all this process for those who want to see all this in more detail and in detail.