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YelloRolla Forums Junkie Location: On your mum! Registered: May 2002	Re: Welding together a wake tower Fri, 11 March 2005 05:45 Welding the tubes together will be easy if you know how to weld aluminum and if you scallop the ends of the tubes where they meet the next section (so as to butt up neatly). I recommend using no less than 3mm wall thickness (thicker if available due to the repeated stress) and using a 6060 construction grade alloy and suitable filler wire when welding. Scaffold tube is suitable and comes as 48.4 x 4.47mm wall thickness. I cannot understand why you would want to make a hat with so many of them available from the cancer council and other specialty hat shops at competitive prices. To fit the spherical bearing ends into the ends of your tube is easy to manufacture a shouldered plug. I imagine the plug to be tapped with the appropriate tap and turned with a shoulder to act as a stop when it is inserted in the tube a small fillet weld to fix it forever. After your alloy work is all done it should be treated by a powder coater who understands that it is to be used outdoors (this is pre-treated differently and uses a different powder). [Report message to a moderator]

	Subject	Poster	Date
	Welding together a wake tower	chrishulbert	Fri, 11 March 2005 05:24
	Re: Welding together a wake tower	YelloRolla	Fri, 11 March 2005 05:45
	Re: Welding together a wake tower	chrishulbert	Fri, 11 March 2005 05:54
	Re: Welding together a wake tower	YelloRolla	Fri, 11 March 2005 05:57
	Re: Welding together a wake tower	Sam_Q	Fri, 11 March 2005 06:11
	Re: Welding together a wake tower	YelloRolla	Fri, 11 March 2005 06:13
	Re: Welding together a wake tower	Sam_Q	Fri, 11 March 2005 06:17
	Re: Welding together a wake tower	YelloRolla	Fri, 11 March 2005 06:18
	Re: Welding together a wake tower	Sam_Q	Fri, 11 March 2005 06:28
	Re: Welding together a wake tower	Ribbo	Fri, 11 March 2005 08:26
	Re: Welding together a wake tower	hokey	Fri, 11 March 2005 08:57
	Re: Welding together a wake tower	Norminator	Fri, 11 March 2005 12:47
	Re: Welding together a wake tower	chrishulbert	Sun, 13 March 2005 23:23

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