I got a referral from my local,welding supplies dealer for a good TIGger and talked about the project with him. (BTW, the shorter tube to be added mated up well using the spline shown.) He pointed out that leaving the wood in there during the weld would likely compromise the joint because of the smo...

Tube in a tube - i thought about that, especially if a TIG weld was in the mix, mostly to back up the weld and add a litle stiffness. Much like you describe. But finding an OD that fits snugly would be tough I think, since I'm dealing with two different tubes that, while they (should) have the same ...

Once I have the "extension" tubing i ordered, if the fit mates well with the long one, i'm going to hunt down a good TIGger. Plan B is for an internal mechanical "plus shaped" (+) splint made of hardwood that will fit tightly in each tubing section. Then countersink and screw thr...

Thanks for the replies! Yup, I had quickly ruled out tackling the TIG work myself, esp after watching Jody's latest video on welding 6061 aluminum. But, given that, I wanted to confirm that this was a doable job for skilled TIG welder. And PeteM, I think I understand your description of an alternati...

I have a length of 2" OD (~.067 wall thick.) aluminum tubing that I need to extend by 2 ft or so. The application requires virtually no structural strength other than to support its own 10' length after the extension. But in eeds to be straight and the joint smooth. My initial thought was to ha...