mhorowit wrote:
I'm not sure I made myself clear. My A&P is concerned about 'stress
risers', but the articles I read about making joints involve a process
which scratches the surface of the tubing and appears to actually
produce those 'stress risers' - Mike


The 'stress risers' will be melted away if the weld is done properly.

If you want to make perfect joints, get a copy of Tubemiter. You input
the dimensions of your tube and the angle of intersection. It prints a
template that you wrap around the tube, then tape in place. Cut, grind
file, up to the marks and be amazed at the 32nd or less of gap. If you
have to fishmouth both ends, print both templates and line them up by
laying the tube on a flat suface next to a board and then lining up the
templates.

You can find a copy he

http://ernest.isa-geek.org/Delta/Library/tubemiter.exe

--
This is by far the hardest lesson about freedom. It goes against
instinct, and morality, to just sit back and watch people make
mistakes. We want to help them, which means control them and their
decisions, but in doing so we actually hurt them (and ourselves)."