I know this has been discussed many times before but I'd like your opinions on my specific tube dimensions if poss.

So, I am preparing the upper harness mounts for being welded and I have some 32mm dia tube and I am going to get the inserts weleded in to. The question is can I use smaller diameter inserts than the commonly used 25mm? (The harness eye bolts are the standard 7/16) I am thinking a 20mm or 25mm dia. insert would not require the removal of too much material on the main cross tube? Picture shows the intersections.

I was going to go down the Haynes route and weld the inserts on the back of the cross bar with the 3mm thick plates surrounding them, but have recently been told that cutting them into the bar itself is stronger.

I struggled a bit to get the tubing so ideally I'd use what I have got, but if I need to get larger dia. tube then I will.

Your thoughts as always are massivly appreciated.

many thanks

Matt

I'd be happy even with a 3 mm wall insert tube, if using a bolt right through. If the inserts are tapped with the thread you would need more wall thickness though.

Cheers

Fred W B