I'm an aspiring race car designer from Phoenix, AZ and I'm using
Solidworks to design a spaceframe chassis for a race car from 1" and 1.25"
round chromoly tubing. The car will be a single seater, maybe openwheeled
car powered by a Yamaha R1 motorcycle engine. Due to the low torque
output and the necessities of racing, weight and stiffness of the finished
car is very important so thinwall (1/16") tubing and plenty of
triangulation will be my design criteria.

So, here's my question ... I am struggling to mate tubes at angles other
than 90 degrees. An example is that, say, I want to attach two tubes,
both round, in sort of a Y configuration similar to the ascii drawing
below:


---------- A
----------
\ \ )
\ \
\ \
B

The tubes can be attached at any angle represented by the ) usually at
angles of 30-150 degrees.

I don't understand the process, within Solidworks, for creating two parts,
each tubes, and then cutting the fishmount on tube B so it fits within a
very tight tolerance around tube B. I understand the actual manufacturing
process which is to use a three axis mill or lathe tooling to create the
end cut on one tube.

FWIW, and for those that don't know, very tight tolerances (.020") are
needed in the fitting of the tubes to avoid or minimize 'pull together' of
the gaps and resulting distortion of the finished assembly.

-Steve