extended pipe/tube - strongest method

[jeffg]

extending pipe/tube - strongest method

I have a project starting this weekend that requires that our 5' pipe panel fencing be 6' tall. The existing fence is square top pipe panels like these:
https://powderriver.com/product/powder-creek-panels/

With some trial and error, 1 1/4" EMT fits perfectly inside the existing uprights. It is tight, but not a press fit or anything.

Would it be better to cut 18" of the EMT and just insert it inside the existing upright and rosette weld it to the upright, or would it better to cut shorter pieces of the EMT and use them as sleeves inside the upright and find another material that matches the dimensions of the existing upright? I think that 1 5/8 line post would be very close.

End result would be a 12" extension on top of the existing uprights.

What do you think?

 

[The Cobbler]

I think either way is fine,whatever pleases you aesthetically I would suggest

 

[PugetDude]

Rosette welds will be a lot easier, and depending on your skill level possibly a lot cleaner.

 

[jeffg]

I agree, rosette welds are in the plan. The real question is the layout before welding.

Do I use the EMT as an internal coupling for a piece of line post, or do I just make the whole thing out of the EMT? Both materials are basically the same thickness (.065 vs .060) so do I really gain anything by adding the second piece of material? Granted the 6" or so where they double up will be stronger, but the top where the cross rail will mount is not.

Seems like it might be faster and easier to just use the EMT alone.

 

[BukitCase]

To me, it'd depend on how much tension I needed (assuming wire) and whether I was containing horses or buffalo... Steve

Also, if tensioning it'd probably help to weld a triangular gusset on each pull point.

 

[jeffg]

Thanks everyone for the input. I have decided to try just using the EMT without the line post. We are actually going to try using a 2x6 for the cross rail. I think that painted white, this will be a very obvious visual cue and hopefully prevent any attempt to jump the panels.

The animal is question is a 6y mare that we will be picking up from the BLM. She is a wild horse that has never really had any positive human contact. We will work on getting her gentled and halter broke and then look for someone to start working on saddle breaking. This is our third BLM mustang and we are very excited to see what she becomes.

 

[BukitCase]

For that purpose the 2x6's should work OK (at least til you find out if she knows how to "crib" - if so, you might wanna go a bit stronger with uprights - then drill 'em and BOLT the 2x6's, makes it pretty quick to replace 'em BEFORE they break in two.

We had horses for years, but none were wild - main thing we learned is that if there's ANY way they can hurt themselves they'll find it... Steve

 

[BD1]

Why not use all square tube ? You could drop in the 1 1/4 emt and plug weld too existing. Then use square tube to drop over the emt. You would have a nice flat surface to bolt 2x6 too.
since existing is square, I would stay with square.