straight vs 45 deg joint

admin

What is everyone's opinion on joining two corners of box tube? is it better to put flat end to flat end or 45 the two ends to make it sealed?correct my terminology if i have anything wrong.
Reply:I think the miter cut and weld looks better, even if you weld a cap on the open end of the one tube.I think if you fit flat end to flat end and don't cap the open end of the tube the joint won't be as strong as the miter. I think if you fit flat end to flat end and do cap the open end of the tube then you gotta take time to cut a cap so your not saving much work.I do it both ways depending on what I want it to look like and how concerned I am with the strength of the joint. I think those points to consider are all worth what I am charging you for them.
Reply:If the joint will be exposed to the weather, in my opinion, the closed miter joint will be more weather resistant.I offer three choices: Good, Fast, & Cheap. You may pick two.Hobart AC/DC StikMate LXHarbor Freight AD HoodHarbor Freight Industrial Chop SawDeVilbis 20 Gallon, 5 HP Compressor
Reply:I typically make straight cuts.  I do it because all parts running in the same direction are cuts are the same length and no adjusting of the saw.    If I am going to cap, then I will compensate for the thickness of each of the caps at the ends so the all will be flush. I think straight cut works well for thin metal, because when mitering the outside edge  become thin especially after grinding.  Straight cuts also provide natural grooves for welding so some weld is left if the parts needs to be finished flush.