Speaking of saddle cuts (e.g., TM drum smoker post on 1/18/2010), Instructables has a new posting on making perfect pipe saddle cuts with a bandsaw or chopsaw. For same diameter pipes, the author, samson3000, uses two cuts at approx. 35° close to, but not through, the center of the pipe so there’s a flat spot (as shown above), not a sharp point. An end view of the cut, pictured below, shows a pretty tight saddle.
For a larger pipe saddled to a smaller pipe in the case where the smaller pipe fits in the larger pipe, the angle is increased to 45°, and the cut goes through the center, so there is a point. If you want a non-90° saddle, you can, for example, cut one side at 30°, and the other at 45°. There are many machine-shop illustrative pictures at the Instructables link.
Making Perfect Pipe Saddle Cuts [Instructables]