Square Tube Miter Template — 5/8" Square Tube, 45° + 90° Wrap Set

Printable wrap template set for 45-degree and 90-degree miter corners in 5/8in square tube - BOTH cuts in one set. Developed from the square-tube unfold: wrap width = perimeter 4 x 0.625 = 2.500in. The 45-degree joint is cut at 22.5 degrees, wave amplitude = 0.625 x tan(22.5 deg) = 0.259in peak-to-peak by trig; the 90-degree joint is cut at 45 degrees, wave amplitude = 0.625 x tan(45 deg) = 0.625in peak-to-peak. Faces 1 and 3 are flat (parallel to the bend plane); faces 2 and 4 ramp. Print at 100%, wrap around the tube with the seam on a corner edge, trace the heavy line, cut on it — two identical pieces make the corner. Grip margin 0.75in above and below the cut line. A print-check square is included to verify scale. True 1:1 scale at 96 DPI. Pure geometry — no vehicle fit involved. Works on the outside of the tube, any wall thickness. Test-fit on scrap first.