Hello Wayne,

Thanks for the suggestions. I really am using 100% copper (Alloy 110).

I already figured out the insulating bit when I made the hinges. When I
was welding the hinges on the metal table, I couldn't get a puddle.
When I put the hinge in a little cave of fire bricks, I was able to get
a puddle.

I can try welding two 1' sections of the bar. However, considering that
copper seems to just suck up the heat, I'm not sure it would be a good
test considering that I'll actually be joining a 4' length to a 6'
length.

I like the end cap idea, but not sure how I would fabricate those. I
can always screw on gussetts to the bottom since there will be a copper
panel on the lower portion of the gate that would hide the gussets.
However, gussets on top would be ugly.

When/if I finish this, is this the kind of thing people would like to
see in the drop box?