Easy way to cap square tubing?

[KMinAF]

I have a little project going where I am using 1" .060 square tubing and I need to cap the ends. Just wondering if anyone could share their techniques for capping such thin and small tubing.

 

[PCustoms]

They sell plastic caps that you tap in.

Other way is to get some 1" strip, lop off a few squares and we it on. If I want a square look, I'll run a taller bead and grind the corner, otherwise I usually round it off for paint.

 

[Paulski]

https://www.mcmaster.com/#47045t56/=1b0iz9v

http://steel.kingmetals.com/search?...re&view=list&w=Square Tube Plastic Plugs&rk=1

 

[kkroger]

Yep, I could do several things, I could program up a part on the CNC mill whittle them out and knock em on there, you don't mention if they need to be metallic or plastic or Welded or not etc... I could cut em out on the plasma from similar material, dress up the edges on the belt grinder or hard wheel and weld them on, MIG, TIG or whatever... I could BUY plastic ones, or whatever... I suppose I could grab a piece of similar flatbar and walk it over to the bandsaw, set a stop and start cutting them out, or I could walk to the ironworker and begin doing the same...

 

[PugetDude]

Don't know what you have for tools, but I'd get a strip of 1/16" x 1" bare steel flat stock and set up a stop for the chopsaw.
You can make the caps as fast as you can advance the strip. With a quick clean up on the bench grinder you're ready to weld them on.

 

[larry_g]

I usually just fit a wooden plug. Is this plug of yours structural, decorative, used for sealing, or???

lg
no neat sig line

 

[KMinAF]

I am making cabinet doors for an office credenza. I need to have a smooth finish across the frame so plugs won't really work. Cutting patches and tacking them in place is the only technique that I know of but with such thin gauge its difficult to not burn through.

 

[bullnerd]

Miter the corners?

 

[lis2323]

I’ve welded them closed and used plastic also.

Another alternative is these metal caps. I have a box of 1”somewhere. Sorry I can’t remember the source as it was many years ago.


Edit. Just noticed you mentioned caps won’t work. Do a good fit up and you can prob tig weld it without fill rod.

 

[kkroger]

Bandsaw chunks of square solid that fit in the end and Blast Tack em in place?

 

[PCustoms]

In that application I would have definitely mitered the corners. Couple minutes to set the saw, then cut everything in one setup (flip the stock for the opposite side). I have some corner clamps that I would use to square everything up, then I would lock the clamps down on the table and have an instant jig for the next few weldments.

 

[MP&C]

Corners:

 

[kkroger]

If I couldn't weld .060 without burning through I'd probably just quit... I weld 18Ga regularly. that is

 

[lis2323]

Here’s the rounded weldable steel corners I used for one of my welding carts.

 

[tarbellb]

It can be tricky if you dont get much gun time.

My suggestion:

_ Cut 1" flat bar as close to 1"x1" as possible, error on + side.

_ Grind back the edges on the tube at 45º

_ Place 1" tab on tube and weld, if you are worried about blowing through then pulse or spot weld. (also point your gun more to the flat bar, not the tube)

_ Grind smooth, repeat as necessary for pin holes etc...

There is no easy or fast way to do it.

 

[steel 35]

Corners:

Thanks for sharing reminds me of some bed frame angle iron I stared at for a while that was cut pretty darn fancy.

Thin metal turn the wire speed down just guessing mig! < Not you MP&C

 

[kazlx]

For thinner stuff I try to make the plugs fit inside. Then you can weld them in slightly inset/below flush. Then grind flat and easier to leave a flat face. Goes quick on a disc sander with a jig. Can always use slightly thicker material for the plug.

 

[alexb2000]

Here’s the rounded weldable steel corners I used for one of my welding carts.

Where did you get those corners? That cart looks great BTW.

 

[lis2323]

Thanks!

My local metal supplier ordered them in for me from his distributor. Probably made in China.

These 2" aluminum 90 degree bends were "massaged" to follow the roofline of the cab protector on my pickup truck.

 

[sqznby]

I am making cabinet doors for an office credenza. I need to have a smooth finish across the frame so plugs won't really work. Cutting patches and tacking them in place is the only technique that I know of but with such thin gauge its difficult to not burn through.

You can cut plugs using thicker material and slightly larger than the inside diameter. Bevel the edge and tap beveled edge inside and tack in place.
Putting the heat on the thicker material will prevent burning through.

Will you be Mig welding or Tig welding?

 

[rsanter]

Miter the corners?

This

 

[iagsxr]

https://www.aa-mfg.com

 

[sberry]

Weld downhill on some thin pieces. I like the rounded corner Robert did on those, real nice.

 

[moreover]

I only just started TIG welding. The most satisfying thing so far has been fusion/autogenous welds. Cut the cap roughly the same size as your tube and melt the two together. I could do each cap in less than a minute easy.

 

[LeeG]

I cut a piece of 1" flat bar to no more than 2' long. Lay the end over your open tubing and tack it on 2 sides. Then use my portaband to cut it off flush. Weld the edges and bind smooth. Much easier for me than trying to precut a bunch of 1" squares.

 

[Bellaireroad]

Here’s the rounded weldable steel corners I used for one of my welding carts.

Nice cart, where did you get those corners?


Sent from my iPad using Tapatalk Pro

 

[zmaxmotorsports]

Corners:

Beautifull work,as usual.

 

[lis2323]

Nice cart, where did you get those corners?


Sent from my iPad using Tapatalk Pro

Mine came from my local steel supplier. They’re available in steel and aluminum. Not certain about SS. HTH

 

[BD1]

If worried about burning through, get 3/16 x 1 or even 1/4 x1 flat stock.

 

[kursplat]

too late now, but next time you can leave the horizontals long enough to cap the verticals, by cutting off 3 sides of the horizontals. weld and grind flush