Next prepared a sleeve out of the same tubing with about 3/8 inch sliced out of it so
it will slide into the tube.
Left short tabs on the head tube for strength and as a welding backer.
Drilled a couple of holes through the outer tube to "plug weld" as well as edge weld.
Welded.
My welds are not the pretty Tig welds, but strong.
Using an old miller 200 Mig, turned down.
Hey, this thin stuff is not easy for me, do it anyway.
I learned on real metal, 1/4' to 1/2" thick or more. Truck parts, dump truck bodies, flat beds,
90,000 lb rated Pup trailer hitches and such.
Anyway, once the tube is welded, time for clean up.
Use angle grinder, flap sander, and in places a light touch with a cut off wheel.
Now the tube is attached. How will it look in the sunshine?