How do you weld your 90 degree joints with angle iron

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I was just wondering how everyone welds there angle-iron when making, for example a square. Do you just cut the ends a 45 degrees with the chop saw or do you actually notch it out. I have always cut at 45 degrees, but I am interested in the pros and cons of notching it out. Also I would like to know the best way to notch it out. Thanks, Nick
Reply:I do both methods..But to "notch" them out you need a band saw.....zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:I have done it both ways depending on whats available to make the cuts.  When using a torch to make the cuts I find it easier to notch as I can do that more accurately than a 45.  If a saw is available I would use a 45.I don't know if there is a significant difference in the structural  strength of one way versus the other.  I am sure some of the other guys will know.
Reply:Ive only notched so far.  When you notch, there is more distribution of material, their is more weld area.  Dont know if it really strengthens anything.  Notching also makes for nice flush 90 deg on cross pieces.Various GrindersVictor Journeyman torch200cf Acet. 250cf oxygenLincoln 175 plus/alpha2 gunLincoln v205t tigLincoln 350mpEsab 650 plasmaWhen you can get up in the morning, Its a good day.Live each day like its your last.
Reply:I do it both ways..... depending on what I'm building, but I always bevel the edges._________________Chris
Reply:I notch mostly, beats settings a saw to 45 degrees when most of my cuts are 90 degrees.  You can notch with a chop saw, if you must. I use a band saw mostly. For heavy stuff I use a torch.
Reply:Thanks for all the replies, I think im going to try notch method tommorrow and see how I like it. Does anyone happen to have a picture of the finished joint?? Thanks, Nick
Reply:Originally Posted by trailgooseDoes anyone happen to have a picture of the finished joint?? Thanks, Nick
Reply:Hey thanks lotechman, that was exactly what I was looking for and it helped out alot.
Reply:I have heard that, as Doolittle says, notching provides more weld area and therefore, a stronger weld.  This, of course, supposes that your weld is as strong as the original material.  Someone somewhere must have done some destructive testing to come up with an answer.  I have used both methods so I'd be interested in knowing
Reply:If you were to visualize a corner connection being loaded with some twisting and bending action it is very unlikely the weld would fail no matter how poorly it was done.  What happens first is that the legs of the angle buckle and twist until the angle is no longer what you can call a load carrying structure.  In my experience when we have been given a drawing with 45 degree joints on the angle the engineer never hesitates to allow us to use a coped connection.  I find that 45 cut joints need extra attention to ensure proper penetration.  The ends of the cuts often have to be bevelled to get proper penetration.  This is extra work where a properly cut will provide a full pen weld at the outside corner.
Reply:I tried this method out and it works great! It took me a little longer to do this, but I think it looks more professional and I will definately start using this method. Thanks for all the replies. Nick
Reply:Your welcome.Various GrindersVictor Journeyman torch200cf Acet. 250cf oxygenLincoln 175 plus/alpha2 gunLincoln v205t tigLincoln 350mpEsab 650 plasmaWhen you can get up in the morning, Its a good day.Live each day like its your last.
Reply:I use an angle grinder with a 4.5" cutting abrasive cutting blade to notch 1"x1"x.125" angle iron.***************************************Lincoln AC225 stick welderLincoln HD100 WeldPak flux core wire feed welderThree of the cheapest grinders money can buy