i am currently designing a frame for a greek week chariot and was wondering for the corners of our frame which of the following 90's is more structurally sound...

note: we are using 1" x 1" boxed 6063 aluminum... and the paint drawing is not to scale

 

for something like that i'd go with the 45's, it's cleaner and it leaves less possibilities for sharp edges and people like to stick their drunken hands in to ****. i believe it's also more structurally sound than the butt joint.

 

45s.

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by ManBearPig4silly &raquo;</TD></TR><TR><TD CLASS="quote">45s. </TD></TR></TABLE>

 

Assuming you will weld the seams all the way around..... The 45 degree cuts will yield more surface area to weld.

We have done both setups for some equipment at work (conveyor company) and experienced tube failure with the straight cut joint. The tube ripped off of the structure when the lack of integrity in the open end gave way.

The straight cut joint doesn't look as nice but is much quicker and uses less overall material. Since you are using 1" x 1" tube it must not be for anything hard-core (the tube failure mention above was a 4" x 4" x 1/4" thick steel tube). I would assume either would work fine.

My vote would be for the 45 degree for looks more than anything.

 

45 degree angle will be cleaner and should be stronger because both pieces have 20% more possible welding contact.

 

sweet...bump for the night crew so i can punch my friend in the ovaries at a 45 degree angle...