Pardon me this might be a bit wordy...
I have started a new project chopping a old Suzuki GS450. This will be my first project where the welds need to be strong AND look good. It is also something that I will not have many chances to practice doing before I actually have to do the real thing. I might have 1 or 2 practice attempts with the materials I have. In the past either my welds didn't have to be so pretty or I had plenty of time to practice to get it dialed in correctly. So I'm coming here looking for advice from people that may have done this before or something similar hoping to gain as much knowledge as I can before I start.
So here's the situation. I'm extending the downtubes on this stock frame by 1 1/2". I've cut out 2 1/2" and I will be replacing that with 4" extensions. The stock frame is very thin, 1 1/8" outside diameter with a 1" inside diameter and is probably made out of ERW tubing as it definitely has a seam. The extensions are DOM tubing but with a thicker wall, 1 1/8" outside diameter and a .875 inside. I made slugs out of solid 1018 mild steel and turned them down so they would fit inside the extensions and stock frame. The extensions and stock frame will be drilled for rosette welding to the slugs and the seam where the extensions meet the frame will be beveled.
My question to you folks is what settings would you start with to accomplish this using a Hobart 187?
Here are some pictures to illustrate what I am talking about.
Downtubes on frame cut:
Extensions with the slugs sleeved in. Extensions are now drilled for rosette welding to slugs but that is not pictured:
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