Building Custom Exhaust Bends with Pie Cut Templates

What Is a Pie Cut Exhaust Bend?

A pie cut bend is made by cutting wedge-shaped pieces from straight tubing and welding them together to form a smooth curve. It's how custom exhaust shops build headers and downpipes without expensive mandrel bends.

Choosing Your Cuts

More cuts = smoother bend, but more welding. For most exhaust work: 3 cuts for a 45° bend, 5 cuts for a 90° bend. PunchMapPro templates handle the math and give you exact cut patterns for each piece.

Print and Cut the Templates

Each piece gets two pages — left half and right half. Print at 100%, tape the halves together at the centerline, then wrap around your tube. Mark the top and bottom cut lines.

Assemble the Bend

Cut each piece, number them, and assemble in order. Tack-weld each joint, check alignment with a straight edge through the bore, then finish weld. The result is a smooth, professional-looking bend.

Tips for Clean Results

• Deburr all cut edges before welding
• Use a back-purge for stainless steel
• Alternate tack positions to prevent warping
• A rotary table helps with consistent welding
• Sand and polish for a show-quality finish