DIY elbow for 45-degree cable tray

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 finderCutting tool (angle grinder with metal cutting disc or shearing machine)Deburring tool or fileCable tray connectors and hardwareSafety gear: gloves, safety glasses, ear protectionStep-by-Step ProcessMeasure 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.

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.

Deburr and Smooth: Remove sharp edges using a file or deburring tool to prevent injury and protect cable insulation. 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.

Optional Finishing: For durability and corrosion resistance, consider surface treatment such as painting or galvanizing. Tips for Accuracy and SafetyDouble-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.