Center tack and weld the flats first . Then center tack and weld the
inside corners a quarter at a time alternating sides . Good clamping
can't hurt . And small beads are going to pull less than big ones .
Don't you have a wire welder ?
That's what I thought. I bought the acetylene tank after the
blacksmithing class last year and haven't gas welded anything this
large yet, and want to try on something non-critical like this tee
that I can saw apart and do over.
Based on experience with similar square tubing joints on the sawmill
frame I plan to weld the outside flat joints but not the inside
corners, then grind flush and add triangular gusset plates.
The sawmill's open-ended ladder frame stayed straight until I welded
the rungs' inside corners, then cooling shrinkage pulled the outer
ends together and I had to jack them back parallel.
The ladder frame ends have to be open to install the bandsaw blade.
I once stick welded a 3/8" plate to another 3/8" plate, in a tee. There
was only inside corners & I was astonished how much the plate was bent
by the cooling weld. When you consider how little leverage the weld
has, the force has to be extreme.
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