bends VS welds

[Bug]

is this acceptable on a smaller buggy. Instead of bending the roll bars, can they be cut. fish mouthed and then weld a gusset of some kind to it ? 
about 500 pound total wieght for finished buggy just to give more info.
Thanks

[Doug Heim]

Looks good to me. I would trust that. Better than some methods Ive seen to get away from bending. I would even go as far as to say that right there may be stronger!

[komelika]

I'm no expert, but I would probably gusset the inside radius of the joint instead of welding to the side of it. Still looks strong to me as long as the welds penetrate.

[BDKW1]

Nothing wrong with that other than ascetics. It would have looked so much better if the tube end cap and gusset were all one piece.

[komelika]

Would it be overkill to gusset from the front as well? Probably, huh?

[SPEC]

When I first started building that's how I did it...I'm with BDK...It would be easier and look way better with the gusset as the end cap
But that looks pretty good Buginator

[fabr]

There has been a lot of discussion about the pros and cons of gussets in a frame. Some say that the gusset spreads the load over a larger area and others feel that the gusset just encourages failure at the ends of the gusset. IMO your gusset will accomplish making that joint stronger but POSSIBLY adding stress at the ends. At any rate I think your gusset in a 500# car will be more than adequate. I do agree tho with the gusset and end cap being one piece would be a neater approach.

[Hammerworks]

That gusset was added after the cap was already there,to add strength for a larger motor.

I worked for a drag race fabricator who swore mitering(frame rails) was stronger than bending,because bending ultimately thins one side of the bend(especially on rect. tubing) and thickens the other.

[BDKW1]

Mitering is only as good as the guy doing the welding. Bending is pretty is inherently a lot more consistent.
 
Gussets will promote cracks at the ends of them if the rest of the structure isn't rigid enough. I would have tapered them down to a thinner point at the ends.

[Engineer]

+1 to all comments.    Bends look nice sometimes.....  Structurally your good.

For a one time car builder an investment in a bender for 10-15 bends is a bit crazy.  Measuring miter cuts are a lot easier as well.

[fabr]

Mitering is only as good as the guy doing the welding. Bending is pretty is inherently a lot more consistent.
 
Gussets will promote cracks at the ends of them if the rest of the structure isn't rigid enough. I would have tapered them down to a thinner point at the ends.

Good point.

[Carlriddle]

How bout holes, larger one in center and a smaller one on each side.  Weaker???  Would make it tad lighter, but I think the holes look much better.

[komelika]

For a one time car builder an investment in a bender for 10-15 bends is a bit crazy.  Measuring miter cuts are a lot easier as well.

I see your point here. But, I did buy a bender for my first project. I kind of look at it like buying text books for a class. I want to build a buggy and learn how to bend instead of paying someone to do it. Besides, like text books, the bender can be sold when I am done with it. Then again, I may keep it for another project down the road. My daughter will need something to follow dad in when she gets old enough.

[fabr]

My sentiments exactly.

[SPEC]

Mine too even tho my bending center left to pay the bills