DN 25 pipe saddle template: 90° tee, 45° lateral and the mitre cut, printable 1:1

Three templates to wrap round a DN 25 pipe, 33.7 mm (1.33 in) outside diameter: the saddle (fishmouth) for a 90° tee on a pipe of the same size, the 45° lateral, and the 45° mitre cut of a two-piece 90° elbow. Each prints at full size, tiled on A4 or Letter sheets with a check ruler, and comes with its table of heights for marking the pipe with a tape and a square. The wrap is the pipe circumference, 105.8 mm (4.17 in).

90° tee saddle

The branch cut to sit on a main of the same size at 90°: the deepest saddle, 16.4 mm (0.65 in) from the flanks to the crotch. The seam of the template goes on the flank of the branch, and the crotch falls in the middle of the wrap.

Print the 1:1 template (PDF) Other pipe, angle or wall: open the calculator

Heights for marking by hand

From the seam of the template, every 3.3 mm (0.13 in) round the pipe; heights from the square end, in mm.

#	Along the wrap	Height
0	0.0	17.2
1	3.3	17.5
2	6.6	18.4
3	9.9	20.0
4	13.2	22.1
5	16.5	24.6
6	19.8	27.5
7	23.2	30.7
8	26.5	33.6
9	29.8	30.7
10	33.1	27.5
11	36.4	24.6
12	39.7	22.1
13	43.0	20.0
14	46.3	18.4
15	49.6	17.5
16	52.9	17.2
17	56.2	17.5
18	59.5	18.4
19	62.8	20.0
20	66.2	22.1
21	69.5	24.6
22	72.8	27.5
23	76.1	30.7
24	79.4	33.6
25	82.7	30.7
26	86.0	27.5
27	89.3	24.6
28	92.6	22.1
29	95.9	20.0
30	99.2	18.4
31	102.5	17.5
32	105.8	17.2

45° lateral saddle

The same two pipes at 45°: the cut runs from 17.3 mm (0.68 in) on the short side to 57.4 mm (2.26 in) on the long side, and the crotch is no longer in the middle of the wrap.

Print the 1:1 template (PDF) Other pipe, angle or wall: open the calculator

Heights for marking by hand

From the seam of the template, every 3.3 mm (0.13 in) round the pipe; heights from the square end, in mm.

#	Along the wrap	Height
0	0.0	51.0
1	3.3	51.1
2	6.6	51.5
3	9.9	52.2
4	13.2	53.1
5	16.5	54.1
6	19.8	55.3
7	23.2	56.6
8	26.5	57.4
9	29.8	50.0
10	33.1	42.4
11	36.4	35.4
12	39.7	29.2
13	43.0	24.2
14	46.3	20.4
15	49.6	18.1
16	52.9	17.3
17	56.2	18.1
18	59.5	20.4
19	62.8	24.2
20	66.2	29.2
21	69.5	35.4
22	72.8	42.4
23	76.1	50.0
24	79.4	57.4
25	82.7	56.6
26	86.0	55.3
27	89.3	54.1
28	92.6	53.1
29	95.9	52.2
30	99.2	51.5
31	102.5	51.1
32	105.8	51.0

45° mitre cut (two-piece 90° elbow)

One cut at 45° across the pipe: two pieces cut like this, one turned half a turn, make a 90° elbow. The cut runs from 20 mm (0.79 in) to 53.7 mm (2.11 in) along the pipe.

Print the 1:1 template (PDF) Other pipe, angle or wall: open the calculator

Heights for marking by hand

From the seam of the template, every 3.3 mm (0.13 in) round the pipe; heights from the square end, in mm.

#	Along the wrap	Height
0	0.0	20.0
1	3.3	20.3
2	6.6	21.3
3	9.9	22.8
4	13.2	24.9
5	16.5	27.5
6	19.8	30.4
7	23.2	33.6
8	26.5	36.9
9	29.8	40.1
10	33.1	43.3
11	36.4	46.2
12	39.7	48.8
13	43.0	50.9
14	46.3	52.4
15	49.6	53.4
16	52.9	53.7
17	56.2	53.4
18	59.5	52.4
19	62.8	50.9
20	66.2	48.8
21	69.5	46.2
22	72.8	43.3
23	76.1	40.1
24	79.4	36.8
25	82.7	33.6
26	86.0	30.4
27	89.3	27.5
28	92.6	24.9
29	95.9	22.8
30	99.2	21.3
31	102.5	20.3
32	105.8	20.0

How to use a wrap-around template

1. Print at 100 %, never "fit to page", and measure the ruler on the sheet: if it is short, the printer scaled the page.
2. Join the sheets on the crosses, cut the template along the curve and wrap it round the pipe with the straight edge square to the pipe; tape it on.
3. Scribe or mark the curve, cut outside the line and grind to it. On a saddle, bevel the cut towards the inside so the branch seats on the main.

Questions

How do I make a %{size} pipe saddle template?

Wrap a paper template round the branch: its length is the pipe circumference, %{wrap}, and its height at every point is the distance from the square end to the cut. The 90° tee saddle above is that template, printable at full size, with the heights every %{step} for marking by hand.

Does the template depend on the wall thickness?

Not when it is wrapped round the pipe: the paper sits on the outside, so these templates are drawn on the outside diameter, %{od}. A branch cut from flat plate and rolled is different: its pattern is on the mid-thickness, and the calculator does that one.

What about a branch smaller than the main, or another angle?

Open the calculator: it takes any two diameters, any angle up to 90° and the wall, draws the saddle and gives the heights. The full-size template of a custom job is free too, with an account.