On Wed, 16 Apr 2008 18:29:50 -0700, David Harmon
wrote:

On Wed, 16 Apr 2008 12:09:32 -0700 (PDT) in rec.crafts.metalworking,
jw wrote,
Never understood why something that was nearly the opposite of
engineered was "over engineered".

"Over engineered" does not mean too much engineering. It means
engineered to meet requirements way "over" the actual real
requirements. HTH. HAND.

With 1/4 inch wall tube perhaps it could be drilled and tapped and
assembled with cap screws. Then weld the cap screws in so they can't
loosen and fall out, and put a couple of good beads in for good
measure. That way you can assemble it loosely, square it up, tighten
it, and weld it. Gussets can easily be put on then after it it is
squared Match drill to tap drill size, remove gusset, tap rail and
ream gusset to fit bolt. Bolt on the gusset, and then weld as
previously described.

Or lay it all out, drill and tap and assemble with gussets - make sure
everything is square, tighten all the cap screws, THEN weld the
mitered inner and outer corners and everything you can reach with the
gussets on, remove the gusset, weld the rest, grind joint smooth where
gusset fits, bolt on the gusset, and then weld the gusse on as well.

Basically your bolted gussets "fixture" the assembly for welding, and
the provide a bit of "feel-good" backup. Use half inch UNF cap screws.
Just make sure you are not trying to drill and tap the welded seam of
the tube!!!!!!
** Posted from http://www.teranews.com **