Got a chart of what sq. tubing fits inside other sq. tubing

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It's maddening sometimes trying to find what square tubing fits inside other square tubing.  For example, I have an application where I need 3/4 Sq. 11 wall gauge to fit inside 1" sq.  11 gauge which I have plenty of, won't work because it is too tight because of the inside weld on the tubing and the application is to long to try to sand the weld down.  12 gauge wall would be perfect but I don't believe local steel yard carries it in stock. I am probably stuck with 14 gauge and a sloppy fit. Any tables you gents are aware of that give sliding fits for square tubing and pipe for that matter, I am always screwing around trying to figure that also.
Reply:Order the material with the flashing removed. Any steel supplier that I have ever dealt with can get it.http://all-a-cart.comWelding Cart Kits and accessories
Reply:Flashing removed?  Had no idea it was available, I assume it is special request?
Reply:Some suppliers carry it in stock, others you will have to request it.For example, 2.53" "oversize" or "trailer Hitch" material already comes with the flashing removed so the 2" receivers will slide right in.http://all-a-cart.comWelding Cart Kits and accessories
Reply:check out this  http://bbs.homeshopmachinist.net/sho...re+tube+broachanother link http://bbs.homeshopmachinist.net/sho...re+tube+broachsome where I read where they were using a chain to pull through the tube but dont see that article at the momentLast edited by fredf; 08-01-2009 at 11:56 PM.-- fredLincoln 180C MIG
Reply:Fred--thanks for the links I actually have a few 3/4" tool bits that I had contemplated using the jam and cram method of flash removal.  But frist I tried a small belt grinder I have.  It quickly turned into work and I could see a real job happening for the 8 feet of this stuff I need. I could also see that tool bit lodged in there better than an Alabama tick.So on to plan B--go to the local steel yard tomorrow and see if I can buy or order 20 feet. Zfab thanks for the tip.
Reply:You also could go to a farm supply store or farm equipment dealer ship to buy it.  It is the basic component of the PTO drive shafts that drive the mounted or stationary equipment. These shafts and tubes are nearly machine fit, with a little bit of grease.  Keep in mind you will be asking for the old American style draft shaft material and not metric.  Depending on PTO Hp requirements,  you will find various sizes of those tubes.  On the seriously heavy duty stuff, you may only find a solid inner bar with the hollow outer tubing.  However, from the sounds of it, most of your material will be lighter duty and should be able to get both in inner and outer tubings instead of inner solid shaft.Esab Migmaster 250Lincoln SA 200Lincoln Ranger 8Smith Oxy Fuel setupEverlast PowerPlasma 80Everlast Power iMIG 160Everlast Power iMIG 205 Everlast Power iMIG 140EEverlast PowerARC 300Everlast PowerARC 140STEverlast PowerTIG 255EXT
Reply:Lugweld--Thanks for suggestion, I wish I had a Tractor Supply or Big R somewhere close, I believe the closest to Phoenix, is Cortez, Co. about 350 miles. There are however a few tractor suppliers that I bet I could do something with.  That will be Plan C if the steel yard is a wash.  Thanks again for the suggestion.
Reply:You should find a tractor dealer somewhere....I would hope....Esab Migmaster 250Lincoln SA 200Lincoln Ranger 8Smith Oxy Fuel setupEverlast PowerPlasma 80Everlast Power iMIG 160Everlast Power iMIG 205 Everlast Power iMIG 140EEverlast PowerARC 300Everlast PowerARC 140STEverlast PowerTIG 255EXT
Reply:You not going to find a chart that takes into consideration the weld seams because they are different from different mfg's.  The math isnt hard to figure out, and if you need it to fit tight either get it with the flashing removed like mentioned or grind a seam in the inside tube.  Ive done that a few times for square driveshafts with no ill effects.Have we all gone mad?
Reply:I've ran into that problem before. Not wanting to have to run into town to buy a piece of the right size stuff I'd use my grinder and grind a shallow groove down the middle (or wherever the seam is) on the inside tube. Granted I wouldn't want to have to do a bunch of pieces but it'll get you out of a bind...Mike
Reply:lock joint tubing sells telescoping tubing but you gotta buy 5-10 thousand feet at a time.