Tube End Cap Clamping System

[Jigantor]

Many times I have had to weld an end cap onto a round or square tube to finish a project.
Not being much of a round tube welder I always hate this part of the fabrication and in fact I try to avoid it.
A part from trying to do an ali bicycle frame weld (which I am not at that level) the other issue is clamping the end cap onto the tube. Sure if the tube is short no problems but what if you are working on a table leg or something even longer, then it gets harder. You have to hold the end cap in place while you get it centred and then tack weld it.
Many times I have dipped my welding helmet to find a clamp has moved.
Enough of that.
Today I started fabricating a tube end cap clamp that fixes to the end of the tube right where it needs to be welded.

Ji

[aametalmaster]

Nice work. I don't cap fancy parts like yours but i do cap steel tube at work....Bob

[Jigantor]

Thank you for the kind words Bob.

Ji

[Jigantor]

6mm Thick ali angle to 15mm thick ali flat bar.
Tacking is really required or the flat bar will bend at the cut when the heat gets applied. Had to twitch the bar a little in my press to keep it dead straight.
Welding over, now for some drilling and finishing.

Ji

[Jigantor]

Finished !
Works great and does not look to bad to boot.
Can clamp round tube from 20mm to 75mm and similar for square tube.

Time to start welding on some end caps on those projects.
The difference this time is that I am looking forward to it.

Ji

[Pat]

JI,

I agree, short pieces are easy enough to find a way to clamp the ends on. Several months ago I had some pieces that were about 5.5 feet long. To position the end caps I modified some magnets that stuck to the tube, and would also hold the cap in position. It works pretty good, and they do sell a magnet clamp that will do the same thing. It is basically 2 magnets held together by adjustable plates that can be placed and locked at various angles. I wish they would come out with an aluminum and stainless magnet.

[Jigantor]

Hi Pat,
I have tried to use magnets to hold fixing tabs on a chrome moly dirt bike frame while I TIG welded the tabs on. The arc deflection due to the magnets made the job impossible. As you also say magnets can not help as holders on SS or ali. I only weld ali, SS & chrome moly.
I do weld mild steel some times but not that often & not tubes usually angle.

Ji

[Jigantor]

I just discovered a great byuse.
Trying to clamp a fixing tab onto a SS or aluminium tube is not easy.
Well no matter where along a tube you would like to weld on a fixing tab the end cap clamp can hold it in position while you tack it.

Ji

[slow50]

cool tool.

[Jigantor]

Hi Slow50,
Thanks for the kind words.

Ji

[Jigantor]

My clamping system holding round tube to round tube.
This was a bit of a pest in the past too.
Now it is a breeze.

Ji