How to weld 1"x2" bar to each other?

[Doofy]

I would read up some more and practice some on some scrap to make sure you are getting good penetration. When done, clamp your welded up practice pieces in a sturdy vise and work it over with a big sledge hammer. If your welds hold, you done good and can proceed with your project.

Good welds don't have to be pretty but they must have good penetration. Good Luck.

 

[CoyPatton]

I would also suggest that you get everything setup as it needs to be to work for your SSQA and attachments. Then mark it all well and take it to a welding shop that works with thick stuff frequently.
I do a decent job if I do say so myself on up to about 3/8” with very good penetration and ok with 1/2” thickness. Once beyond 1/2” thickness, I take stuff to someone who does it regularly. It is my opinion that when the material thickness gets greater the stress factors increase and potential dangers of injury on failure increase greatly.
My $0.02 worth. Probably over priced at that!

 

[Egon]

Beveled both sides and a welder with sufficient amps for penetration and flow.

 

[Gordon Gould]

This might be worth watching

Old School Stick Welding still Rules. 611, 718, anyone?

gg