Otto Nobedder wrote:From a metallurgy standpoint, E70s-6 Mig wire or ER7018 stick (or ER7014, for that matter) will give you both sufficient strength and sufficient ductility to withstand wind stress and it's own weight.
From a design standpoint, notching and welding on the bias is the best choice you could have made for ultimate strength. This significantly increases the length of weld, and puts the weld in favorable positions for the loads it will see. It virtually eliminates sharp corners, thus eliminating stress risers. It also eliminates welds that are perpendicular to the line of load.
I also think it will be more attractive as a finished product than simply square-butting it.
I couldn't agree more! And thanks for the feedback! I'm actually planning on only having 2 stopping points per side. Gonna start out welding overhead/vertical up and then once i hit the corner of the square tubing I will be welding vertical up, kind of. More of a 6G type angle than actually overhead since it will be suspended during assembly so I can get underneath it. I don't know if that makes sense but basically I am trying to limit my starts and stops as much as possible and will probably feather stops and tacks before welding into or away from them.