Thats a great idea- One would need both an over and an under-mounted bearing for doing the 45 degree part of the angle, or perhaps something like this: http://www.toolstoday.com/p-5004-double-bevel-trim-cutter-assembly.aspx I just cleaned all of the aluminum chips out of my shop last friday, but it ...

Here are some pics of a sample I TIG'd up today. I think I am going to pull the trigger on this next week. it came out pretty durn square, after a few prototypes. I've done a few at this point, and think I've got my tacking order such that it comes out square and not obtuse or acute. I would be very...

Revs, Check out this video that Jody did awhile back and you'll get a good idea how your metal moves while welding. Just because your welds are in line with the piece being welded doesn't mean they move in that line while being welded. http://welding-tv.com/2014/05/07/welding-distortion-fundamental...

Dave- All good points you make. I feel that the potential problems that you point out with this type of job(from hell?! Lol) are mostly solved by a flat assemble table and square welds, consistent distributed heat input. It's when one of your joints opens up and /or one of the corners pulls out of 9...

Coming along well. I'm taking some time to dial this in before I really start production so as to avoid the SNAFU possibility. I built myself a quick table for this job as I mentioned previously in the thread. http://itisaprocess.tumblr.com/post/111810501400/nice-big-8-x-7-assembly-table-for-upcomin...

Yes, I would too! But from what I've read it seems that since all the welds are rectilinear to the frame the warpage is minimized. The miter has the potential to magnify warp because it has the possibility of creating more radial movement.

About what temp would you preheat this too? Also, does anyone use a coped joint for this application? More cutting obviously but intuition tells me there is less opportunity for warpage.

Thanks for the pointers. I'll go TIG up a few more samples and see if I can't get that consistent dead 90 degree miter before I go cutting up 12' lengths.

Hi All- I will be making a run of large 12' x 7' frames made from the aforementioned 2" x 2" x 3/16" 5053 aluminum angle. They are to be mitered, welded, ground down and powder coated. There may be some kind 'strainer' to keep it rigid for transport and painting. I've done some alumin...

Indeed! All 5 Inches! Whew! its turns out, like so many things in this city, that storm was way over hyped.

Hi All- Long time lurker here. I've been dipping in and out of welding for about 15 years now, I also do a lot of woodwork. I usually do custom fabrication of one sort or another, no two jobs are the same (which is a great way to keep it interesting... and make sure I don't ever make too much money ...