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Splicing Tubing
Splicing Tubing
Ever ran into a situation where you needed to splice a tube but didn't want to just butt-weld it?
Published by $CEEP
02-16-2006
Splicing Tubing

Ever ran into a situation where you needed to splice a tube but didn't want to just butt-weld it? Follow along as Nate shows us a GREAT way to overcome this problem!




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This came to me for repair a few weeks back.
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After cutting out one bar i was hoping to be able to grind the old weld out and just re-weld it. Alas... That wasn√*t going to happen.
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As you can see, someone just didnt have a clue.

So now I√*m stuck with a problem.. i have this gaping hole, that is in a main hoop. To remove the entire tube would entail basically re-doing the entire front 1/2 of this cage. Not going to happen.

So how can i get a good splice in there?

1. Remove section
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2. Fit replacement piece. (Note drilled hole)
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3. Fab interior splice (Note washer welded to end)
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Here√*s where it gets tricky.
If you notice in the crappy picture from step one there is a hole in that tube that the removed section covered up. Luckily for me it was a thru hole, in the factory bar.

Insert your interior splice into your replacement tube with the washer at the coped end. Now place the splice in place.
Using a hammer and drift pound the interior splice into the mating tube, (drift inserted through hole in existing tube) until you can just see the end of it through the hole noted in step 2.
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Then weld it all up
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This should yield you a splice that 1) accomplishes the job and 2) is stronger than before.

Happy fabbing.
$CEEP

Written by Nate Schuit ($CEEP)
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  #1  
By dirtgrip on 03-07-2006, 11:37 PM
Nice fix-I used your idea to lengthen some control arms.Cut-turned out some plugs-drilled a few holes-slipped 2in extension on plug & had a friend Tig the thing together.Lots stronger than it was & the right length to boot.
  #2  
By quad-ryder on 10-19-2006, 10:30 AM
Totally lost me, A through hole in the factory bar,
WHAT? so factory bar is junk? there should NOT be any holes through a cage ANYWHERE !!!maybe I'm not understanding your concept here but looks like entire cage needs to be scrapped.
  #3  
By fabcam on 10-19-2006, 11:35 AM
Quote:
Originally Posted by quad-ryder
...maybe I'm not understanding your concept here ....
Yep. Nice first post.
  #4  
By $CEEP on 10-19-2006, 11:39 AM
Quote:
Originally Posted by quad-ryder
Totally lost me, A through hole in the factory bar,
WHAT? so factory bar is junk? there should NOT be any holes through a cage ANYWHERE !!!maybe I'm not understanding your concept here but looks like entire cage needs to be scrapped.
i beleive the through hole in the factory b-hoop was to accomodate a bolt for the optional front spreaders.

all factory jeep cages have holes in em. seat belts, softop hardware, option cage pieces. etc. etc.
  #5  
By quad-ryder on 10-19-2006, 12:13 PM
well there ya go, I missd it(the type of cage)i was thinking off road race car cage ,dont know about jeeps
opps (my bad)
  #6  
By quad-ryder on 10-19-2006, 12:37 PM
Quote:
Originally Posted by $CEEP
i beleive the through hole in the factory b-hoop was to accomodate a bolt for the optional front spreaders.

all factory jeep cages have holes in em. seat belts, softop hardware, option cage pieces. etc. etc.
didnt know was a jeep, im on the same page now.
  #7  
By dirtgrip on 10-19-2006, 09:52 PM
From what is was to what it is now is a complete turnaround IMO.Maybe you should post a pic of your cage quad-ryder.
  #8  
By dirtgrip on 10-19-2006, 09:54 PM
Last edited by dirtgrip; 10-20-2006 at 09:03 PM.. Reason: duplicate post
  #9  
By cjtpi on 01-31-2007, 11:11 AM
you can fish mouth the two connecting tubes to add some strength
  #10  
By TheBandit on 02-13-2007, 04:12 PM
Quote:
Originally Posted by cjtpi View Post
you can fish mouth the two connecting tubes to add some strength
I saw this done when installing threaded adaptors into the ends of link tubing. The fishmouth gives more weld area.
  #11  
By cjtpi on 02-15-2007, 01:38 PM
Quote:
Originally Posted by TheBandit View Post
I saw this done when installing threaded adaptors into the ends of link tubing. The fishmouth gives more weld area.
i saw it done to a tube aircraft. they inserted a slug rosetts held in place left enough space to get the weld bead from the tube to the slug then another bead from the other tube to the slug
  #12  
By tsm1mt on 03-29-2007, 01:00 PM
Quote:
Originally Posted by quad-ryder View Post
well there ya go, I missd it(the type of cage)i was thinking off road race car cage ,dont know about jeeps
opps (my bad)
Every sanctioning body I've raced with wants a 1/4" hole in my off-road race car roll cage so they can inspect the wall thickness of the tube.

Definitely want it in a "non-critical area", of course.
  #13  
By DevinSixtySeven on 07-25-2008, 02:20 PM
How much gap do you leave between tubes for the final weld around the outside?
  #14  
By offroadbuggy on 02-10-2009, 12:24 AM
nice repair man! work looks excellent


BTW,in one of the above posts someone mentioned "fishmouthing it",what is that? is that a variation of notching/saddleing?
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