NO WELD JOINT

Portable MIG welding is very expensive out

in the country. I'm limiting it's use to the

outer, structural parts of wall frames and 

the interlacing member (Non-stress) will

be this method I've devised. Took some time to set up but goes very fast in production.

Drill and counter sink holes in mainbeam. The pink

hole strattle jig made for tooling used here to center.

Countersink below surface. Note I'm using Torx

screws that are 1" longer than tubing.

Using 1/8th cutoff wheel, cut notches on opposite

side of upright. Notice stop plate to make depth from end uniform.

Clean burrs, square end and camber

bevel all four edges.

Clamp to jigging square (tooling)(I use 2" Kwik clamps), make a bunch of 

1" x 1" x 1/8th squares to act as cinch nut.

Align and tighten.

Clean joint surfaces well with lac thinner.

Heat joint with propane (cheaper). Braze
with MAPP gas (hotter) (Home depot)

Aluminum melts at 1100 degrees, braze rod

(Home Depot)at 600. Do a side and allow to cool.

 Working around all all 4 sides continuously allows

residual heat to melt aluminum. I made the insert

nut plate larger here to illustrate it coming thru.

The rest are flush fit. After cooled, remove screw, coat

threads with locktite and reinstall....tight!!