Welding Inside a Tube?

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I'm not a welder at all, but I need a steel bracket welding to the end of a pipe. I have thousands of these to give to a welder. I dont want to look like a total newb so I thought I'd ask this community what would be the best / easiest way to weld this bracket to the end of the pipe.I can re-design how the bracket meets the tube, but I cant change the tube. The tube is a actually a scaffolding pipe. Please see attached drawing, thank you in advance.Will Attached Images
Reply:What is the id of the pipe?
Reply:The ID is 40.60mm
Reply:They should be able to run a fillet in that mig or tig
Reply:Thanks Tig Monster do you think its easier to run a fillet inside or to weld all the way around a pipe, if i made the bracket a circular end cap?   see attached
Reply:Originally Posted by Will HillThanks Tig Monster do you think its easier to run a fillet inside or to weld all the way around a pipe, if i made the bracket a circular end cap?   see attached
Reply:It will need to hold about 100kg
Reply:Originally Posted by Will HillIt will need to hold about 100kg
Reply:Perfect thanks Tig Monster, you have given me the confidence that the welder isn't going to laugh at my drawings
Reply:I would notch the tube, insert the pad eye in the notch. Make the pad eye just a little bigger than the ID of the tube.Don’t pay any attention to meI’m just a hobbyist!CarlDynasty 300V350-Pro w/pulseSG Spool gun1937 IdealArc-300PowerArc 200ST3 SA-200sVantage 400
Reply:CEP I think I'm with you, check the attached drawing, did i get the right idea from your description?
Reply:That would work, assuming you want the weld flush with the OD of the pipe. If the weld can stick up above the OD of the pipe, your pad eye can be all the way out to the outside wall of the pipe. That makes it a bit easier to get the pad eye located properly for welding..No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:That’s exactly how I would do it. Plenty of weld volume, and easy access to make the welds. I use to do a lot of rigging. This picking frame picked 300-tons, the webs, and flanges of the beams are notched out for the pad eyes. When I built my bridge crane, I notched the web of the truck beams, and inserted the pad eyes. Attached ImagesDon’t pay any attention to meI’m just a hobbyist!CarlDynasty 300V350-Pro w/pulseSG Spool gun1937 IdealArc-300PowerArc 200ST3 SA-200sVantage 400
Reply:Thank you all for your input, I feel you have given me the best solution, seriously, thank you! Last edited by Will Hill; 08-03-2015 at 08:44 AM.
Reply:One more, if the bracket is 5mm thick, should I cut the notch in the pipe at like 5.1 or 5.2mm wide to give some tolerance to allow the bracket to slide in easily?
Reply:I would think, if the bracket is just narrow enough to slide into the tube, but not slide through the notches, the fit up would naturally preclude the bracket from sliding too far one way or the other, sort of self-jigging.Edited due to bad mathIs the 220 lbs. static?Last edited by geezerbill; 08-03-2015 at 09:33 AM.Hobart Beta-Mig 2511972 Miller AEAD-200LEMiller 250 TwinNorthern Ind. Hybrid 200Longevity Stick 140Longevity Migweld 200SThermal Arc Pak 3XR