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Youtube idea for removing a weld seam in rectangular or square tube

A convenient idea for sure. I used to use the all thread with cutter method for runs longer than my burr.

A warning however- some folks might be tempted to do this fro making their own receiver hitch. The seamless tube used for that is actually DOM so it isn’t just no seam but much stronger material and no seam. For that stuff spend the extra cash and buy the right material.
 
There is also another method to get a tight fit for seamed tube. Look at the horrible freight Pittsburgh gantry crane upright square tubes where I saw it.

Use a flat "bushing" to resize an inner dim's of outer tube. You can grind a groove out of the back of the bushing to saddle over the seam on the one side or remove enough weld seam out for the bushing to sit flat. You just have to use an oversize outer tube big enough to make the bushing(s).

They tap the bushing and screw through outer tube to secure it on the Pittsburg gantry crane for assembly. And assume they reverse on the inner tube (screw the bushing from the inside to make a male bushing for the inner tube). This can make a solid stop so you can't pull the inner tube out all the way in one direction. You could do it different ways depending on the application.
 
You asked for it so don't laugh at my sketch it was a quick attempt at a cross-section to try and show (1) bushing or spacer. You need (4) to center the inner tube or you could do (3) and the inner tube would be pushed over to one wall (without weld seam) of the outer tube. In my drawing, I show the bushing or spacer notched to saddle over the outer tube's weld seam. Or you could grind the weld seam down for the bushing depending on how long you can reach in and or make the bushing. Pittsburgh's gantry crane tube appears to use a ~ 2-inch long bushing or spacer.

Next time I am at a harbor freight store I'll try and take a picture with my phone of the crane on display. This is the best one I could snip from google images. I don't have one of these cranes
 

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I once designed a small crane into a trailer or pickup truck. with a maximum carrying capacity of 1 ton. boom from standard shaped tubes, this seam could be a problem.
Screenshot_20170707-171537.png
 
I stopped by horrible freight today. I’m not tall enough to get good pictures but between my sketch and pics it shows the concept.

Leave it up to the Chinese to figure the cheapest way to do things. It’s not much of a bushing. They only capture the corners with their spacer/bushing. Sort of makes sense as corners are strongest and compared to a short spacer across flat the corners would less likely make a stress point in sidewall that would encourage a crumple effect maybe.
 

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