Bend or cut an weld to angle 2x4 tubeing

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I'm planning my sports cage build for my jeep this weekend and I found another guy who did the same. However I'm copying him by replacing the factory jeep crossmember that ties the cage together with a 2x4 3/16 thick rectangular tubing. The pictures are found here http://www.jkowners.com/forum/showthread.php?t=54682My question is how can I bend this? I've called locally and no one can bend 2x4 tubing. I do not have a torch or a bender but I could buy one if I could get it for a feh instead bucks.My other option is to cut each end of the tubing and re weld the gap with the ends at the angle needed to match the stock crossmember. Would this significantly weaken my crossmember or would this be okay assuming I put a nice 5/16 bead when I re attach it.Please help me find the most practical way to do this!!!! I would rather not send it off anywhere since I would like to start my cage this weeken. I will no mig welding if that matters. Thanks!
Reply:Cut out a "pie slice" that corresponds to the angle of the desired bend, then bend the gap shut, and then weld up the three cut sides. Be sure to bevel the material where it will be welded, so you can get as close to 100% penetration as possible, and you should be just fine.Ian TannerKawasaki KX450 and many other fine tools
Reply:You could always add a gusset, and then you know it's strong enough
Reply:Is "jk" in "jkowners" short for junk?
Reply:if you are attaching this to the stock cage its going to be almost twice as thick as the factory sheet metal tubingMiller Xmt 350Lincoln Ln-25Ahp 200xSmith Gas Mixer AR/HTig is my Kung FuThrowing down dimes and weaving aboutInstagram http://instagram.com/[email protected]
Reply:Originally Posted by rdop2001Is "jk" in "jkowners" short for junk?
Reply:I wasn't trying to offend you I was just making a little joke. I forgot the smiley though.