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Reply to "Newbie with many questions"

JMM (Michael) posted:

So here's a thought late in the game, but I just got back from camping a long ways from internet.

Instead of bending the steel plate you have, leave it flat. Cut two right triangles the length of the side that piece and 1.5" wide at the end. Get out your 1" hole saw and notch the 1.5" end of each triangle to match the 1" tubing. Weld those pieces to the long sides of your original piece creating an open boxed piece to weld onto the 1" diameter tube. This should give you a nice strong piece and lots of weld surface, without having to bend that hefty plate. You could probably use steel that's the same thickness at the wall of the tubing to make the welding easier and the piece lighter without sacrificing strength. The piece is essentially in tension (it's a hanger), and the boxing of it should give you the lateral strength needed. Run one up out of cardboard first, and when you've got a good pattern go to it.  Repeat for the other side. 

Alternatively, notch the 1"tubing to the depth of the piece of plate. Fit in the plate and weld away.

Not too late.  Was practicing welding yesterday, so I have not actually started welding yet.  Still need more practice welding.  I will draw up your idea and see if I have it right.

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