How would you make this joint

[neonnblack]

2x2 sq tube vertically with a 1x2 sq tube horizontally, connected at the ends. I'm trying to minimize welding and grinding (more or less grinding) time, since im grinding all welds down so everything is flat.

Should i just weld a "cap" to cover the opening or cut it like so:



Or maybe there is a better way and im over thinking this?

 

[retrobuilder]

Hint..rotate the 1x2 with 2" side vertical. Miter full 45 cut and weld and grind.

Simpler
easier cutting,
less welding and
much stronger counter top..

 

[ADSR]

Nothing wrong with the notch. Either way, burn it in hard and you'll ne golden.

 

[retrobuilder]

and I'd have "legs" ? continuous and cut horizontal pieces to but to side of 2x2.

Less welding and pieces and straighter?

 

[skyking]

Cut fine , Ziggy papers , roll tight..............................oh uh wrong thread.

 

[t100]

I'm trying to minimize welding and grinding (more or less grinding) time, since im grinding all welds down so everything is flat.

try tig?

 

[ilovevocs]

It's difficult to determine from the sketch what it is that your building. My approach would vary based on the intended use of this piece. Is the design of the joint being driven by functionality, aesthetics, or both?

 

[ADSR]

Cut fine , Ziggy papers , roll tight..............................oh uh wrong thread.

 

[Zeke]

Why not cut an angle straight across the joint?

 

[neonnblack]

It's a head board. And foot board. It's matching my desk so out needs to have the 1x2 flat which is why i can't just 45 both, our id have a gap. consider it ornamental. And i wish i could tig it all and not grind any thing.

 

[nine4gmc]

I would do the 2x2's solid and **** weld the 1x2s to fit inside the "legs", flush with the outside.

 

[zkling]

It's a head board. And foot board. It's matching my desk so out needs to have the 1x2 flat which is why i can't just 45 both, our id have a gap. consider it ornamental. And i wish i could tig it all and not grind any thing.

For what you are doing that is going to be fine. Actually that is probably the cleanest way to do it in the end. If you take your time, you will end up with a seamless joint. Your other option would be a cap as you said. Technically they both could end up looking the same, but I think your way would be a bit easier.

Since you are not putting any load on the top piece it is fine in the orientation you have drawn.

 

[welder4956]

A crude sketch with MS Paint, but perhaps you could arrange the smaller tubes flush with the outside of the 2 x 2 similar to the sketch.

 

[neonnblack]

Only problem with making it flush is i would then have to cut out a cap and weld it on then grind it all down and try and make the corners look normal. With the "zig zag" i only have to worry about one corner. Thanks for the input guys.

 

[Sureshot]

Just cut the 2" down on three sides and leave the outside on the 2" to cover the end of the 1x2". Better than trying to fit that bevel.

 

[kazlx]

Just cut the 2" down on three sides and leave the outside on the 2" to cover the end of the 1x2". Better than trying to fit that bevel.

That's what I would probably do. Leaves a continuous piece on the outside and makes an easy joint to prep. How thick is the tubing? The thinner it is the more problems gaps will be.

 

[racingtadpole]

My 5c worth..
Cut it carefully with an angle grinder and v the edges before welding, try to keep the bead as flat as possible when you're welding.

 

[bullnerd]

Material?
Tools available?

 

[Kevin54]

Cut fine , Ziggy papers , roll tight..............................oh uh wrong thread.

I just KNEW someone would beat me to it

 

[neonnblack]

I figured someone would do it, lol. .060. Steel. Flux cored. Now I'm stuck between the zig zag or the notch. Notch would be much easier to fit up, but more finishing work.

 

[MoonRise]

More than one way to do it, but I think that your original proposed zig-zag is just making more cutting and fitting work for yourself.

pssst, btw, a 1x2 is not "square".

OK, let's see, you have 2x2 posts and 1x2 rails, with the rails 'flat' so the 2" dimension is horizontal. You're welding it all up and grinding the welds flat, and you don't want the tubing to be left 'open' (close or cap the ends).

Like I said originally, although your proposed zig-zag cut would work, I think it will be more cutting and fitting work for yourself.

Three choices I'd go with would be:

- make 'inset' caps that go in the 1x2. Plain straight cuts on the 1x2 and 2x2 pieces. Weld caps into the ends of the 1x2, grind flush and flat. Lay 1x2 on top of the 2x2, weld, grind welds flat (only not easily ground weld would be the inside fillet weld at the inside corner of the 1x2 onto the 2x2).

Pluses : Plain straight cuts on the hollow tubes. Straight welds joining the tubes.

Minuses : Possible fussy fitting of the inset caps into the 1x2 tubes.

Alternate : Put the caps on the 2x2 posts, weld and grind flat/flush.

- Miter the corners, not doing the zig-zag. The angle won't be a 45, but a 30/60 (depending on which face/leg you measure/reference off of).

Pluses : One cut on the tube end, jsut it's an angled cut.

Minuses : Angled cuts (some folks freak out with angled cuts). Having to weld an outside miter-cut corner (if the fitting is off, you have a gap to try and weld on an outside corner).

- Make a 'cope' cut on the 2x2, leaving just the outside vertical 'skin'. Square cut on the 1x2, lay it on top of the 2x2 and butting up against the remaining 'skin' of the 2x2. Weld and then grind flat/flush.

Pluses : Straight cuts.

Minuses : Just have to take a little more time and effort to make the cope cut.

I'd probably go with Option #3.

 

[gahrajmahal]

If you're going to see the welds when finished your original idea is the best looking to me. If I saw that, I would say to myself, dang, sweet joinery even with unfinished welds.

 

[bgoodwin]

Another crude picture with ms paint.

 

[Fyrme]

This joint is kinda what you are trying to do I believe. I did this due to the angle of the arched piece and the desire to have as much material contact as I could get. I laid the vertical piece over the arch and marked it with a sharpie. I used a cut off wheel to make my cuts. The result was a tight joint that was easy to weld with the mig.

 

[welder4956]

You could notch the 2 x 2 out like the sketch below to slide the 1 x 2 pieces in and not need to make any caps.

 

[bullnerd]

Good vertical bandsaw with a miter gage.For the number of notches you need.No brainer.

Do it the way you want it or you'll regret it.

 

[welder4956]

Good vertical bandsaw with a miter gage.For the number of notches you need.No brainer.

Do it the way you want it or you'll regret it.

I agree. Good reason to buy tools if you don't have what you need to do it. I have a DeWalt portable band saw mounted on a SWAG table that would make this an easy job to miter or notch.

http://www.swagoffroad.com/SWAG-V30-Portaband-Table_p_55.html

 

[theoldwizard1]

Another crude picture with ms paint.

This get my vote !

No weird angles to cut. Weld all edges and grind. The inside edge will require a burr on a die grinder or a Dremel and a whole bunch of 1/2" diameter sandpaper drums !

 

[neonnblack]

I have four of these joints to do. I have an idea - im going to try each corner each way and report back what was best. I dont have time constraints or anything, i actually cant start until next month on this part anyways. It will be fun trying out the different ways, learn a thing or two also. Thanks guys.

 

[neonnblack]

So, i did the project, well part way through anyways. The best way (for me) was taking the 1 inch notch out of the tube like in post 28.

Trying to cut a sharp angle was far to difficult with the 4x6 band saw, very hard to get everything lined up.

My original plan just was far to time consuming and needed to be very precise to work well.

The notch only took a minute each corner with the grinder to get it correct.