Fusion welding DOM race car tubing

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ive been searching around on here but havent found any posts matching my inquiry. only posts about fusing stainless. im looking to fusion weld .095 DOM round tubing and various mild steel. the little i did find sounds like ill be safe but i wanted to ask and get a solid answer. thanks in advance.
Reply:Hello tourillegal, is there a specific reason why you only want to fusion weld the DOM? Bead concavity and under-cut could possibly limit the strength of the joints and subject them to cracking or failure under loading. I suppose the purpose of your project could better determine whether you should consider fusion welding or the use of fillers. Try to include a bit more detail as to grade and diameters of the DOM and also it's intended use. The folks here will be much better able to give you suggestions. Best regards, Allanaevald
Reply:Why wouldn't you want to add filler?My name's not Jim....
Reply:Simple answer, NO. Fusion welding will not be sufficient.http://all-a-cart.comWelding Cart Kits and accessories
Reply:Originally Posted by aevaldHello tourillegal, is there a specific reason why you only want to fusion weld the DOM? Bead concavity and under-cut could possibly limit the strength of the joints and subject them to cracking or failure under loading. I suppose the purpose of your project could better determine whether you should consider fusion welding or the use of fillers. Try to include a bit more detail as to grade and diameters of the DOM and also it's intended use. The folks here will be much better able to give you suggestions. Best regards, Allan
Reply:Originally Posted by tourillegal a few reasons to not use it is weight, cost and time.
Reply:Hello once again tourillegal, considering your intended application, I might make these suggestions: as you are likely going to be welding protective cage components and other structural and safety oriented parts you definitely don't want to scrimp on the filler. Weight in racing of the amounts that might be saved by fusion over filler are so minimal that, as another posted mentioned, "skip the cheeseburger" really does apply. When you are considering the weight that you should be concerned with, you should really consider concentrating on rotating mass, that's the stuff that really counts. Back to fusion welded joints, unless you spend excruciating amounts of time cutting, fitting, re-cutting, and grinding, you would still end up using fillers to make up for fits.      Do a simple test, take some 11GA. material and make up 2 T-fillets, on one of them weld one side of the joint with fusion weld of an 1/8" size, on the other one use filler and weld one side to an 1/8" weld size. Flatten both of them by pressing/hammering the vertical portion of the T over flat leaving the welded side exposed. It is very likely that the fused example will split down the middle of the weld bead and the other example will just bend flat with out fracturing or breaking. I believe you will see the concern that others have expressed here with the results of this example. Best regards, Allanaevald
Reply:obe wan kenobi would say "Use the filler Luke, use the filler"When push comes to shove and it all goes pear shaped, the bloke whose butt is in the seat won't begrudge the extra weight. It should sit more easily on your conscience too.Weight saving, drill holes in non critical items, as advised earlier, skip the cheeseburger and the fries, take a dump. There'd be more savings to be had there than in skimping on possible weld strength.Last thing I'd want to see in a wreck is a failed weld.Just my .02 cents worth."One of the things we have to be thankful for is that we don't get as much government as we pay for." (Charles Kettering)Mitch 180 (NZ)Lincoln SAM-400-220 + ?-400 Fordson Major + 2 x Tractapac Humber 80 + Procut 40 PlasmaMiller Spectrum 375
Reply:Originally Posted by ZTFabSimple answer, NO. Fusion welding will not be sufficient.
Reply:No filler and you will NOT pass tech inspection..And if you do then go to another track....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:Originally Posted by tourillegalThe DOM tubing sizes are 1.5 and 1.75 both with the .095 wall. used for asphalt circle track racing... did a test weld earlier today and didnt seem to have much under-cut if any at all. but i didnt do a thorough test just a visual so far.I dont wanna use filler if i dont have to(safety is definatly first priority) a few reasons to not use it is weight, cost and time. but like i said.. safety first. all the joints will be tight fitting obviously.
Reply:No way around it, as everyone has said, use filler.Esab TradeMaster TorchSmith AW1A Airline TorchLincoln AC/DC 225/125Millermatic 252 w/ Spoolmatic 15aThermal Arc 190 GTSSpeedGlas 9100v
Reply:your racing in a circle a pound of filler means nothing but a safer car
Reply:well like i said if it needs to be used it needs to be used.. but ur wrong on the weight. there is about 20+ pounds of weld on a full tube chassis car like i run. i would much rather add that weight to make my percentages.. but if filler is needed its needed. i did say safety first.
Reply:Use the filler.  If you want to lighten the weight, use custom made butted tube, which is thicker at the ends and thinner in the middle.  This is how bicycles are made to be both strong and light weight.  Cost will be through the roof for a custom butted tube set though!MM350P/Python/Q300MM175/Q300DialarcHFHTP MIG200PowCon300SMHypertherm380ThermalArc185Purox oaF350CrewCab4x4LoadNGo utilitybedBobcat250XMT304/Optima/SpoolmaticSuitcase12RC/Q300Suitcase8RC/Q400Passport/Q300Smith op
Reply:Originally Posted by DesertRider33Use the filler.  If you want to lighten the weight, use custom made butted tube, which is thicker at the ends and thinner in the middle.  This is how bicycles are made to be both strong and light weight.  Cost will be through the roof for a custom butted tube set though!