Compound Elbows: 3D Printed S Offsets and Two Plane Bends, Stainless or Aluminum, 2in to 4in

Compound Elbows: 3D Printed S Offsets and Two Plane Bends

Two bends, one part. Each compound elbow joins two 0.75D bends with no straight section between them, metal 3D printed in one piece. Cut your tube, butt weld both ends, and the double bend is done. No pie cuts, no clocking two separate elbows to each other, no tack, check and re-tack.

Pick your shape

• S offset (two 30s, two 45s or two 90s): two bends in the same plane that turn back the way they came, so the ends come out parallel and shifted sideways. Use it to jog a pipe around a crossmember, frame rail or tank without changing direction.
• Two plane (45 and 45, or 90 and 45): the second bend is turned out of the plane of the first, so the pipe moves in two directions at once. The 45 and 45 changes direction 60 degrees overall and the 90 and 45 changes direction 90 degrees overall. A mandrel bender cannot make a two plane bend in one piece.

Pick your material

• 316L Stainless: for exhaust. Welds to 304 or 316 stainless tube. Body wall is 0.049in, with a 0.065in weld band running 0.30in along the bend at each end.
• Aluminum (AlSi10Mg): cold side only (intake, intercooler, charge pipe). Never exhaust. 0.065in wall throughout, to match 16 ga aluminum tube.

Never use the aluminum parts on exhaust. Printed aluminum loses most of its strength above about 200°C (390°F), far below exhaust gas temperature. For anything on the hot side, choose 316L stainless.

Built for fabricators

• 0.75D centerline radius on both bends: the radius is 0.75 times the tube OD.
• No straight legs. The bends run end to end for the tightest packaging.
• Butt weld ends made for 0.065 wall (16 ga) tube of the same OD.
• Tube OD 2in, 2.13in, 2.25in, 2.36in, 2.5in, 2.75in, 3in, 3.5in and 4in.
• Bead blasted finish.

Dimensions

For the S offsets, the offset is the sideways distance between the two parallel tube centerlines, and the second number is the length from one end face to the other along the pipe. The two plane bends are listed by the overall box they fit in.

• 2in OD: S offset, two 30s: 0.40in offset over 1.50in. Two 45s: 0.88in over 2.12in. Two 90s: 3.00in over 3.00in. Two plane, 45 and 45: fits a 3.06 x 2.15 x 2.68in box. Two plane, 90 and 45: fits a 4.27 x 2.15 x 2.50in box.
• 2.13in OD: S offset, two 30s: 0.43in offset over 1.59in. Two 45s: 0.93in over 2.25in. Two 90s: 3.19in over 3.19in. Two plane, 45 and 45: fits a 3.25 x 2.28 x 2.84in box. Two plane, 90 and 45: fits a 4.54 x 2.28 x 2.66in box.
• 2.25in OD: S offset, two 30s: 0.45in offset over 1.69in. Two 45s: 0.99in over 2.39in. Two 90s: 3.38in over 3.38in. Two plane, 45 and 45: fits a 3.44 x 2.42 x 3.01in box. Two plane, 90 and 45: fits a 4.80 x 2.42 x 2.81in box.
• 2.36in OD: S offset, two 30s: 0.47in offset over 1.77in. Two 45s: 1.04in over 2.50in. Two 90s: 3.54in over 3.54in. Two plane, 45 and 45: fits a 3.60 x 2.53 x 3.16in box. Two plane, 90 and 45: fits a 5.04 x 2.53 x 2.95in box.
• 2.5in OD: S offset, two 30s: 0.50in offset over 1.88in. Two 45s: 1.10in over 2.65in. Two 90s: 3.75in over 3.75in. Two plane, 45 and 45: fits a 3.82 x 2.68 x 3.35in box. Two plane, 90 and 45: fits a 5.33 x 2.68 x 3.12in box.
• 2.75in OD: S offset, two 30s: 0.55in offset over 2.06in. Two 45s: 1.21in over 2.92in. Two 90s: 4.12in over 4.12in. Two plane, 45 and 45: fits a 4.20 x 2.95 x 3.68in box. Two plane, 90 and 45: fits a 5.87 x 2.95 x 3.44in box.
• 3in OD: S offset, two 30s: 0.60in offset over 2.25in. Two 45s: 1.32in over 3.18in. Two 90s: 4.50in over 4.50in. Two plane, 45 and 45: fits a 4.58 x 3.22 x 4.01in box. Two plane, 90 and 45: fits a 6.40 x 3.22 x 3.75in box.
• 3.5in OD: S offset, two 30s: 0.70in offset over 2.62in. Two 45s: 1.54in over 3.71in. Two 90s: 5.25in over 5.25in. Two plane, 45 and 45: fits a 5.35 x 3.76 x 4.68in box. Two plane, 90 and 45: fits a 7.47 x 3.76 x 4.38in box.
• 4in OD: S offset, two 30s: 0.80in offset over 3.00in. Two 45s: 1.76in over 4.24in. Two 90s: 6.00in over 6.00in. Two plane, 45 and 45: fits a 6.11 x 4.29 x 5.35in box. Two plane, 90 and 45: fits an 8.54 x 4.29 x 5.00in box.

What's in the box

One compound elbow in the shape, tube size and material you pick.

Install notes

• Weld on part. Butt weld each end to tube of the same OD and the same material family.
• The ends are made for 0.065 wall (16 ga) tube.
• Professional welding recommended.

Related printed parts

Need a single bend? See the 0.75D tight radius elbows. For laterals see the printed cope junctions, and for collectors the printed 2 into 1 merges. Browse the full 3D printed stainless exhaust parts collection.

Buy the STEP file, $11

Want to print it yourself? Under Material, pick STEP file (316L design) or STEP file (aluminum design) and you get the same 3D model we send to our printing partner, in the shape and size you chose. Every shape and size from 2in to 4in has a STEP file. The download link comes right after checkout and nothing ships. Upload it to any online metal 3D printing service for your own quote.

The file is yours to use however you want. The 316L file is designed for 316L stainless. The aluminum file is designed for AlSi10Mg and is for the cold side only (intake, intercooler, charge pipe).

Parts printed by someone else are not covered by our warranty. Digital files are non-refundable.

Lead time

Printed to order. Allow about 4 weeks before it ships.

For off-road and competition use. Buyer is responsible for following all local exhaust and noise laws.

Designed by Brockett Built in central Illinois. Printed by an outside metal printing partner.