DIY 45-degree elbow for cable trays

A 45-degree cable tray elbow can be made by cutting two tray sections at 22.5° each and joining them to form the desired angle.

Materials and Tools Needed

• Cable tray sections (metal, e.g., galvanized or stainless steel)
• Measuring tape, square, and protractor or angle finder
• Cutting tool (angle grinder with metal cutting disc or shearing machine)
• Deburring tool or file
• Cable tray connectors and hardware
• Safety gear: gloves, safety glasses, ear protection

Step-by-Step Process

1. Measure and Mark: Draw a perpendicular line across the width of each tray section. From this line, mark a 22.5° angle on each piece, ensuring the second piece's cut is in the opposite direction to the first for proper alignment .
2. Cut the Tray: Use an angle grinder or shearing machine to make the 22.5° cuts on both sections. Ensure cuts are precise to maintain a smooth 45-degree bend .
3. Deburr and Smooth: Remove sharp edges using a file or deburring tool to prevent injury and protect cable insulation .
4. Join the Sections: Align the two cut pieces to form a 45-degree elbow. Secure them using appropriate cable tray connectors and hardware, ensuring a stable and functional joint .
5. Optional Finishing: For durability and corrosion resistance, consider surface treatment such as painting or galvanizing .

Tips for Accuracy and Safety

• Double-check angles with a protractor before cutting.
• Wear protective gear at all times.
• Test-fit the pieces before final fastening to ensure the elbow aligns correctly.
• For larger or heavier trays, welding may be required for added strength . By following these steps, you can create a precise and safe 45-degree cable tray elbow suitable for DIY electrical installations or custom cable management projects .