"Dave Baker" wrote in message
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"Dave Plowman (News)" wrote in message
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If I do decide to have a go at welding with my MIG - what would be a good
starting point current wise, etc?

The tube is approx 70mm diameter with a 2mm thick wall
The bush 24mm x 12mm with a 14mm thread already tapped in it.

You don't have an ideal situation if you're trying to glue a flat boss to
a round tube, especially with such a thin wall thickness because you can't
even flat the tube enough to match the boss without breaking right through
it. You could shape the boss to match the tube o/d if you had a lathe or
mill to generate a 70mm diameter curve. Easier to weld it then I'm now
thinking.

If I was doing it I'd flat the tube a bit with a milling cutter, drill a
hole, turn the boss to be a fit into that with a flange and weld round it.
Alternatively I'd set up a flycutter at 70mm diameter, radius the bottom
of the boss to match the tube and then weld that on. I'll do it for you if
you get stuck. I've got loads of spare ally offcuts too if you need to
make another one.

Alternatively, glue the boss to the inside and then tightening the sensor
will just make the joint compress more.