Square Tube Miter Template — 1" Square Tube, 90° Corner Wrap

Printable wrap template for a 90-degree corner in 1in square tube. Developed from the square-tube unfold: wrap width = perimeter 4 x 1.000 = 4.000in, cut at 45.0 degrees for a 90-degree joint, wave amplitude = 1.000 x tan(45.0 deg) = 1.000in peak-to-peak by trig. Faces 1 and 3 are flat (parallel to the bend plane); faces 2 and 4 ramp. Two identical pieces make a 90-degree corner. Print at 100%, wrap around the tube with the seam on a corner edge, trace the heavy line, cut on it. Grip margin 0.75in above and below the cut line. 2.00in print-check square 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.