To gap or not to gap (question to the welders)

[scullyg40]

Which is better for structural strength? With the gap, I can weld the inner sleeve as well, but there is more room between the cage tubes. Without the gap, the cage tubes are closer together, but penetration to the inner sleeve is harder.
The holes are there to connect the cage to the sleeves.

Please let me know what you think.

 

[Louis]

Slight gap surely? You're penetrating the inner tube, but also building onto the exterior. Weld will be strong than the surrounding steel

 

[PhillipM]

Gap the same width as the tube thickness.

 

[dann2707]

Bevel the edges at a 45 degree angle I would say

 

[RuskiWeldFab]

No gap but bevel at 45. When welding 2 bits together, gap in between is usually a sign of bad fitment. It can be filled ofcourse but flush fitment is preferred. With correct settings even with out bevel, weld should have enough penetration anyways.


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[scullyg40]

Thanks for the reactions guys. Bevelling sounds like the right thing to do, albeit that the cage is already in the car with the inner sleeves tacked in. I also do not want to make a cut in the inner sleeve to keep that one as strong as possible.
I will make a couple of test welds to see what's best, before I start welding on the car.

 

[JamesBryan]

Gap the same width as the tube thickness.

This.

Bevel the edges slightly and leave about an 1/8th inch gap between.

 

[scullyg40]

A 3, 4 mm gap seems to make the best connection.

I've got the welder turned up to level 6, 7 is the maximum, and wire feed to 9.

 

[PhillipM]

Should be about right, you want the gap for complete penetration into the sleeve at the right power setting for joining the two outer tubes. Otherwise you have to run far too hot and end up with a big slug of material on the outside.

 

[scullyg40]

That's exactly what happened when I didn't have the gap.