connecting tubes at a low angle

[justin86]

Hi guys, new to this forum, I am making a go kart from some old Mechanix Illustrated plans, and I have a question. Looking at the side view, the bottom and top side rails come together at quite a low angle, the plans seem to call for them to connect for some distance, how should I do that? file the low angle from it? so they meed for 5 or 6" or should I just make them meet at the ends?
Hope you understand, the picture should help.

Thanks for any help,

Justin

[DynoDon]

I have had to do that kind of fabrication before. I usually make the worlds longest fish-mouth to get the lower (in this case) tube to fit flush with the upper. I then TIG weld the entire length, a little at a time as to not warp the upper tube.
I fit them using a Burr King belt sander but with care and patience a half round file will work.
Good Luck

[exwestracer]

Another method would be to slice each tube to the centerline at 1/2 the intersecting angle. the end would look just like the end of a single piece of tubing.

[mikeybigblock]

I agree with dyno. I would make a long fish mouth. Take your time and it will look cool.

[raustinss]

hey guys not to be rude but there are formulas to figure this stuff out im a fabricator by trade ....all i need is to know the tube size (outside) and the angle of the joint i can make a pattern and email or mail it to you . if i mail it il include directions on how to figure this out..way to hard to explain on here . let me know if i can be of any help [email protected]