Lynn,
There is a chap locally who produces tube flanges at right angles directly
out of a piece of tube with a nice radiased edge - I don't know how better
to explain it nor do I know how he does it but it looks like a piece of tube
with a flange with a nice radiased edge at right angles to the tube - it is
not welded but drawn out of the tube itself. Would this work Lynn or does
the tube (with the bell shaped end) have to be extended into the
other larger tube.
George (down under)

When I was plumbing I used a very expensive machine that couls pull a nice port in a large diameter copper pipe. The thing paid for itself the first week we used it. Instead of cutting a supply line twice and installing and adapter, we drilled a small hole in the line and inserted this gizmo that had expanding dies with rollers. It would expand the hole while pulling the spinning rollers out of the hole and made a nice spigot you could sweat in a new copper line.

If you can get it to work on the material you are using, it sounds like a winner. The larger the radius the better, but any radius is better than a square corner.

 
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