Fit-up is 80% of the weld: the clamps, magnets and tricks that make joints square
Difficultyeasy
Buy or make: two 12" speed squares, four welding magnets (the cheap arrow ones are fine), a pair of 90° corner clamps, and a flat surface you trust. Tack in a sequence that pins the geometry (opposite corners), re-measure diagonals, then weld. Expect joints to pull toward the weld side about 1 to 2 degrees; pre-set the angle slightly open or weld opposite sides alternately.
On thin tubing, a 1/16" gap vs no gap is the difference between a weld and a blow-through. Shim with a hacksaw blade for a consistent gap.
#fit-up#clamps#magnets#fabrication#welding
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Tried this over the weekend and it worked first time. Thanks for writing it up properly.
The embedded video is clearer than the official service manual, which is a little embarrassing for the manufacturer.
Right around what the post says, give or take shipping.