Thread: Hatchet Job
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Old 01-19-2017, 07:38 PM
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x-bird x-bird is offline
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Join Date: Oct 2011
Location: Penciltucky
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Thank you. None, when i take these old ones and re-do them I use the existing tubing pieces from the bolt together cages and basically visualize and experiment with how they can be cut and re-used to make something a bit more aesthetically pleasing and structurally much stronger/safer. For this one, I've got 27-feet of new 1-inch tubing into it as well.

If i have to combine pieces to use a pre-curved chunk (like the upper side rail's corner at the back) i slug it internally with another piece of snug-fitting tubing, drill and plug weld the other tube to that and leave a slight gap so the weld penetrates the inside tube and the outer tubing ends at the joint. That allows it to be ground flush.

In the case of that upper rail, i ran new 1-inch into a short piece of curved and plug welded it and then welded the joint at the difference in diameters.
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