Chinese bar stool rebuild

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I have a buddy who owns a tavern and several of his bar stools have become victim to some of his more overzealous patrons.  He asked me if I could take a look to see if I could fix them here's some pics of the first one, it's pretty representative of all 12 stools he brought me.  The material is t-h-i-n thin!  ran a few beads on one that was "beyond repair" and found that I'll need to run my TIG at 30 amps.  More pics once I get some welds complete. Attached Images- If you can jump across it you can weld it!  - anonymous old boilermaker
Reply:I have a friend that imports those chairs from mainland China. $12 each. Good luck repairing that paper thin material.
Reply:I wouldn't repair them.  They're junk when new.  I'm suprised your friend isn't concerned about liability issues with stuff like that.  If you DO repair them, you also subject yourself to potential law suits.
Reply:yeah, i wouldnt even wanna use them at the bar in my own games room
Reply:I'm really just taking it as a challenge against the chi-comms.  Once I did a little grinding the parent material is surprisingly good.  the problem with the original design was the crappy hardware used to fasten the rungs on. The bolts worked loose and the legs started to flex.   I'm gonna weld the rungs and see what happens.  We both discussed liability and he said that's what insurance is for...- If you can jump across it you can weld it!  - anonymous old boilermaker
Reply:I'm really just taking it as a challenge against the chi-comms.  Once I did a little grinding the parent material is surprisingly good.  the problem with the original design was the crappy hardware used to fasten the rungs on. The bolts worked loose and the legs started to flex.   I'm gonna weld the rungs and see what happens.  We both discussed liability and he said that's what insurance is for...- If you can jump across it you can weld it!  - anonymous old boilermaker
Reply:Gussets.  The break tables at work have paper thin tubing that the welds break all the time, the only way to strengthen them is to add gussets or the stuff will just rip out again.  Gussets stiffen the joint while distributing the load across more of tubing.
Reply:So it turns out that my friend wasn't relying on these stools to be put back in service, he ordered some new stools but I finished the one I was working on just have to paint it and put the pad back on, it'll work for a shop stool for a buddy stopping by for a beer.  Here's pics of some of the welds: Attached Images- If you can jump across it you can weld it!  - anonymous old boilermaker
Reply:nice fix!Nothing Ever Got Done By Quitting, Never Give Up.
Reply:I bet its stronger now than it was when it was new. Hard to keep from burning through on that thin stuff, and get good looking beads like that. Nice job!Miller Thunderbolt 225Millermatic 130 XPLincoln HD 100 Forney C-5bt Arc welderPlasma Cutter Gianteach Cut40ACent Machinery Bandsaw Cent Machinery 16Speed Drill PressChicago Electric 130amp tig/90 ArcHobart 190 Mig spoolgun ready
Reply:thanks guys,  I had to run at 30 amps so I didn't blow through.- If you can jump across it you can weld it!  - anonymous old boilermaker