If you’ve ever tried to build something with Furniture Grade PVC pipe, you’ve probably run into this frustrating issue: ordering pipe lengths that are long enough for your project without breaking the bank on shipping costs.
Here’s the situation: to keep shipping costs reasonable, we limit our PVC pipe lengths to a maximum of 5 feet (60”). Why? Shipping carriers impose hefty fees—and those fees only keep climbing—for any package that exceeds 48” in length. To remedy some of these additional handling fees the carriers impose, we began offering 40” lengths to negate some of these charges.
While these workarounds save our customers money, we know they can create pipe length challenges as well. Whether you’re building a patio cover, a greenhouse, or a 9-square game; 40” and 60” pipe lengths often just don’t cut it—literally or figuratively.
What many don't realize is that you can easily create your own custom pipe lengths to whatever length you need, even beyond the maximum shippable 60” lengths. All you need is any length of PVC pipe, some basic tools, and our clever Internal PVC Coupling - a game-changer for longer-length PVC projects.
If you have a larger project that requires a substantial amount of pipe, we do offer our products in 10’ and custom cut lengths on our bulk site, FORMUFIT Direct.
Why use Internal PVC Couplings
The Internal PVC Coupling is a smart little connector that lets you join two segments of Furniture Grade (or Sch 40 Plumbing Grade) PVC pipe segments internally. Unlike standard couplers, this one fits inside the pipe, leaving a smooth, nearly invisible connection. There’s no bulky seam, no change to the outside diameter, and no compromise on strength when cemented place.
Internal PVC Couplings are available in all FORMUFIT colors and we stock them in 1/2 in., 3/4 in., 1 in., and 1-1/4 in. sizes. They are sold individually on formufit.com, allowing you to order just the right the quantity you need for your project.
Creating Longer PVC Pipe Lengths: A Step-by-Step Guide
If you need PVC pipe lengths longer than what’s available, don’t worry! Here’s a straightforward guide to help you achieve the exact lengths you need using Internal PVC Couplers.
Determine the Lengths You Need
Start by deciding the final pipe lengths for your project. Whether you need standard lengths like 6 feet, 7 feet, or a custom size like 79 inches, you'll need to calculate how to achieve these using the available 40” and 60” PVC pipe lengths.
Each Internal PVC Coupling adds approximately 1/8” to 1/4” to the overall pipe length. Therefore, it’s important to consider this factor when taking measurements.
Gather Your Materials
Here’s what you’ll need:
- PVC pipe (40”, 60” or other segments)
- Internal PVC Couplings
- Measuring tape
- Pencil or other marking instrument
- Hacksaw (or another cutting tool)
- PVC cement (optional for permanent connections)
Measure and Cut
- Measure the pipe segments needed to achieve your desired final length.
- Use a pencil or marker to clearly mark the cutting points on the pipe.
- Cut the pipe to size using a hacksaw or cutting tool.
Make straight, 90 degree cuts to ensure the coupling fits snugly and disappears into the pipe for a clean finish.
Prepare the Pipes and Couplings
- Remove any burrs or debris inside the pipe from cutting to ensure a snug fit. A simple kitchen knife works well to scrape off burrs.
- Dry-fit the couplings: Insert the coupling into one pipe segment to check the fit and alignment.
- If you have difficulty inserting the coupling, gently scrape the inner edge of the pipe with a kitchen knife to create a slight bevel.
- Push the coupling into the pipe. If necessary, insert at an angle, then use a hammer or mallet to gently tap it into place.
Cement the Pipes and Couplings (Recommended)
Unless you plan to use the Internal Coupling connection as a breakdown point, securing with PVC cement is the best option as it permanently fuses the pipe and couplings together. This essentially turns two pieces of PVC into one solid, fusion-welded length of pipe.
- Apply a small amount of PVC cement to the inside of the pipe.
- Quickly and firmly push the coupling into the pipe end. Carefully wipe away any cement that may have been pushed out.
- Apply cement to the other pipe segment, then slide it over the coupling. Again, carefully wipe away any cement that may have leaked.
- Hold the joint for about 30 seconds to allow the cement to set.
You can skip this step if you prefer removable pipe segments or if the tolerance and fit is already secure..
Check for Alignment
- Ensure the pipes are aligned and straight before the cement fully cures.
- If you accidentally made the pipe too long, just remeasure and trim it to the desired length.
- Allow the cement to cure according to the manufacturer’s instructions (usually about 30 minutes), before putting it into use.
Put Your Pipes to Use
Congratulations—you’ve created custom PVC pipe lengths! Now it’s time to bring your project to life. Whether you’re building furniture, constructing a garden structure, or tackling a unique challenge, these longer pipe lengths make it possible to design exactly what you imagined.
