Would some of the welding experts here be kind enough to give me a recommendationi on how to weld this up without warping it so bad it doesn't fit anymore?
The application is a crossmember for a TJ engine swap project intended for daily driving and light wheeling.
Plate will be bolted to frame through sleeved holes (not drilled yet), tube is currently tacked to plate. Plate-to-frame tacks will be ground off after I get it drilled, just to keep my holes lined up.
Tube is 2-1/2" x 2-1/2" x 1/4"
Plate is 3/16"
I have at home:
- A Miller 135 with .030" solid ER70S-6, and years of practice
- Ability to run .035 flux core, but I've never done it
- A Victor oxy-acetylene rig for preheating
At work, I have access to a Miller Synchrowave 250 DX TIG, but I just learned how to use it this year. I've done 1/4" with it (all flat or fillet), and I still undercut the edges of my beads sometimes.
So which option will get me a strong crossmember that will fit in the same spot after welding?
A. Keep it in the frame, preheat with the torch, then fill the bevel with several passes with my 110V welder
B. Take it out of the frame, and bring it into work after hours to lay a serious bead with the TIG
C. Give up and take it to a pro?
Thanks in advance for the help!