Welding Process Question

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So I am building this bumper, and I have a question about process. I need to cut up some 1/4"x2" flat bar to close up the horizontal bar so that it doesn't corrode from the inside out. I plan to bevel the edges of the 1/4x2 to provide a nice vee and ensure penetration. To do the welding, do I just tack the 4 corners and then run a continuous bead around the perimeter?Mike
Reply:If you're talking about welding the end caps on, I'd cut the cap small enough to make outside corners on all sides and then fillet welds to seal it up.Weldtek
Reply:Weldtek,I am talking about the end caps, but also I need to put a cover over the bottom where it angles up at the ends. Can you explain what you mean by "make outside corners on all sides"? I am not following what you mean by that.Thanks,Mike
Reply:Sure,If you're closing off a tube and the inside dimension measures 2"x2". Then cut the cap 2"x2", it will fit up corner to corner. Also, if you're putting a bottom plate on it too can be fit up corner to corner. Do you have a brake? Are you bending pieces or just fitting up flat bar?Weldtek
Reply:Ah,You are talking fitting up the pieces so that it fits inside the channel. The 2" is the outside dimension, and I was talking about laying it on top the channel after bevelling for a vee. I don't have a brake, I am just going to fit up two different pieces of flat bar and weld them up. That is why I was asking about tacking each corner to prevent distortion, and then doing the continuous bead.These welds aren't structural, but I still want to do a good job on them.Thanks,Mike
Reply:Here's a quik pic of corner joints.Weldtek Attached FilesCorner joints.doc (23.5 KB, 62 views)
Reply:So if I am looking at that right, the yellow signifies the fillets around the perimeter?Sorry for all the newb questions,Mike
Reply:No, the yellow is th flatbar fitup to make the corners open. The weld goes in the four corners, that way the weld puddle has somewhere to sit. This pic could represent the end of a 2"x2" tube that you fab'd together out of flat bar. Now that it is welded together, the ends would be open and the caps would fit up the same way. As for the bumper pic, the ends that are angled up could be closed off the same way.Weldtek
Reply:tack 3 corners..corner #4 is your starting point for a continous weld..keep the tacs small.. and listen...if you hear a tack break STOP and fix it..if you keep goingthe heat will bend it in the wrong way... ...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 WeldtekSure,If you're closing off a tube and the inside dimension measures 2"x2". Then cut the cap 2"x2", it will fit up corner to corner. Also, if you're putting a bottom plate on it too can be fit up corner to corner. Do you have a brake? Are you bending pieces or just fitting up flat bar?Weldtek
Reply:Nevermind Weldtek...I just re-read your post and you did say INSIDE dimensions of 2"x2".....my bad!! http://all-a-cart.comWelding Cart Kits and accessories