your ideas on a pipe profiling machine

[HiltonSteve]

Just check this video out, it shows what I was trying to explain....

The interesting stuff starts around the 2 min mark, cutting large holes with a plasma, for your design the plasma would be replaced with a small router or Kress with something like a 6mm slot drill. Also it shows the machine drilling holes with a standard drill bit.

Same principle as I was trying to explain though, just an X axis to travel along the centreline of the pipe, an A axis to rotate it and a Z to plunge through, Z would be optional but nice to have! Not sure why you would need a Y axis at all??

You could also cut the ends of pipes so you can create your own 90 degree joints.

Simples....!