I am ready to have a section welded onto my Ultra Frame. What do you recommend as a Frame tube strengthener between the 2 sections before welding.?.
ie. a Solid circular steel bar OR a tubular section to fit the inner dia. of both tubular sections.

 

What year and where on the frame and how long a section? Existing HD frame material or adding new material? Do you have a MIG or TIG welder?

 

when adding a section in the middle of a tube section, it is difficuilt to use a plug on both ends without leaving a generous gap at 1 or both ends. If you have the filler tube, and have already chose to use a plug then you most likely ahve provided for enough gap to engage 1 end full then slide backwards into the other end. The stiffener can be either tube or solid as long as you provide enough material to burn in, usually the same otr thicker than the material you are trying to weld. Seems to me a solid plug would be easiest as you can turn to the correct diameter for a snug fit and burn in with no concern for burning through.

Solid plug gets my vote...

 

I'm a rank amateur at welding, which I readily admit. What Scrmnvtwins says makes sense to me. I'd go solid plug. It would also be much easier than finding just the right OD size tube to use inside the frame tube.

Where'd you wind up getting the frame bit?

 

Yep frame plug Done a couple custom frames this way and race cars. Nice and solid. Just get everything super clean inside and out. Mig or Tig doesnt really matter as long as you have good penetration.

 

That is music to my ears! Straightforward no messin answer.
Thanks SvT and others who responded. Bungo

 

Hi Doc,I eventually got a frame from New Hamps.Mass. The guy obligingly cut out the section I needed and I am picking it up today after 2 weeks in transit.
I have taken a large selection to keep strength and retain geometry. As per yellow lines in pic.Bungo.

 

Hi Doc,I eventually got a frame from New Hamps.Mass. see attached pic.
The guy obligingly cut out the section I needed and I am picking it up today after 2 weeks in transit.
I have selected a large selection to retain strength and geometry.
Any suggestions by you guys as to where to cut and join both frames would be really appreciated.
The Yellow lines are where the guy has cut it.
Ideally I will retain bottom crossmember and upper rear crossmember,the one that braces the two 45 degree frame tubes. Leaving a bit of frame tube where necessary.Bungo.

 

I know its too late but he should have cut it at the square tube tank mount up top.Would have only been 3 cuts Just did a back half that way. On the bottom just make sure your getting all the rust out.Try too do it with the least amount of cuts tack everything,measure measure measure than skip around welding. It pulls these little frames around like a SOB.

 

I could have got the complete frame less the headstock which had been cut off. Problem was Shipping cost. Thats why I minimised frame cuts. Bungo
ps. drove from Manhattan NY to Greenport? LI. NY in 78. Had hired a Motorhome in White Plains NY. First time I had driven a Motorhome & first time driving in the US. It wasnt an easy drive especially as I left Manhattan at peak time!
Was a pleasure to eventually reach Greenport though after the heavy duty 6 lane traffic leaving the city. .