Butt welding tubing

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Hello!First off, I'm a novice. I'm still learning, and best way to learn is just make something.That being said, I have an old go kart that I wanted to extend (make longer). I've seen other people do it on You Tube and other sites and typically when they want to put in a bigger engine.The kart frame is 1 inch tubing with a .065 inch wall thickness.After cutting and determining the proper length tubing to weld in, what would be a good process in butt welding the tubes together?Thanks!!Joey G.Downey, CALincoln PowerMIG 180C
Reply:Originally Posted by JoesEdgeHello!First off, I'm a novice. I'm still learning, and best way to learn is just make something.That being said, I have an old go kart that I wanted to extend (make longer). I've seen other people do it on You Tube and other sites and typically when they want to put in a bigger engine.The kart frame is 1 inch tubing with a .065 inch wall thickness.After cutting and determining the proper length tubing to weld in, what would be a good process in butt welding the tubes together?Thanks!!
Reply:I do .065 wall sanitary tubing all the time. A GOOD!!!! clean cut and slam the edges together, then TIG the joint. The inside of a properly welded joint looks like the outside. Practice makes perfect, this should not be your first big job.Disclaimer; "I am just an a$$hole welder, don't take it personally ."
Reply:We usually cut the tubes at 45* angle then put a sleeve in one tube with 2 or 3 plug welds slide the other tube over the other side of the sleeve, weld the angle butt weld then finish with plug welds on the other end......
Reply:I'm not trying to be an ******* but if you have to ask this question, you really shouldn't be working on anything that moves and/or has stress on it that can cause injury.
Reply:Originally Posted by JoesEdgeHello!First off, I'm a novice. I'm still learning...
Reply:Hmm...you guys are right. I questioned it when I saw videos of people doing it. It just didn't seem safe. Seems like a point of failure and an accident waiting to happen.If I need it longer, I probably should just start from scratch.Although, for future reference...even if I was a more experienced welder would this something that could be done safely?Thanks!Joey G.Downey, CALincoln PowerMIG 180C
Reply:Tozzi is right. Clean nice fit up and fit them up with no gaps and burn it in nice and smooth like. I wouldnt think you would need a ton of filler but my .065 wall exp. is on satinless vaccum jacketed piping for nasa. so if its good enough for those tards. i wouldnt see why you wouldnt be able to do it. if your that worried about it dont do it. BUT if you do it make sure you run the piss out of it and see if u can break it. If you cant then your good to go.
Reply:Originally Posted by jmink427We usually cut the tubes at 45* angle then put a sleeve in one tube with 2 or 3 plug welds slide the other tube over the other side of the sleeve, weld the angle butt weld then finish with plug welds on the other end......
Reply:Originally Posted by oznationTozzi is right. Clean nice fit up and fit them up with no gaps and burn it in nice and smooth like. I wouldnt think you would need a ton of filler but my .065 wall exp. is on satinless vaccum jacketed piping for nasa. so if its good enough for those tards. i wouldnt see why you wouldnt be able to do it. if your that worried about it dont do it. BUT if you do it make sure you run the piss out of it and see if u can break it. If you cant then your good to go.
Reply:slug the tubing at the joints with a smaller tube the same thickness......make sure you have a good overlap (4") . that would be the safer bet than butt welding
Reply:Originally Posted by Zca4I'm not trying to be an ******* but if you have to ask this question, you really shouldn't be working on anything that moves and/or has stress on it that can cause injury.
Reply:I extended my sons go cart years ago and made it even stronger than original. I had been a journeyman welder/fabricator for about 15 years at that point so I never doubted that I could do it. Go ahead and do a simple butt splice at the side rails in a position that doesn't require extending controls too much. Then, truss the frame by adding another rail above a few inches and canted outboard for better entry/exit angle. Put some short tubes between the two rails or a piece of sheet metal. CakeTwo turn tables and a microphone.
Reply:I have streched my old go cart 12" so I could fit my lengthy self in it when I cut it I did a outer sleve out of poo pipe from home depot I drilled holes in the piece it was 30inchs long and plug welded it and welded each end.. I  took it through some serious mud and jumped some ditches with it I sheared off the front spindle and bent the rear axle. I never bent the strech though how I don't kill my self im not sure. The roll cage was a very good thing that Im glad I spent time reinforcing. lolVantage 300 kubota ,miller 304 xmt ,lincoln ln 25 pro , ranger 305 G, plenty of other tools of the trade to make the sparks fly.
Reply:Originally Posted by TexasTWhile not everyone has the ability, or skill at least he is out seeking answers to a question. You can't start out with experience.I would go with the sleeving, inner or outer should work fine.