I decided to weld my hollow fender struts myself. Go big or go home, right? Again, I have no real welding experience and I own a very cheap welder so give me a break when you scroll down and see my welds.
Here's my fine Harbor Freight flux core welder. You don't have to tell me the Lethal Threat decal makes it classy. I know it does.
I used a magnet to hold the pieces in place and tack welded it.
After quite a few passes, here is the result. Yes, there's a lot of splatter and it's not what I would call a pretty weld, but the two pieces of steel are now one and that's all that matters. My angle grinder will clean it up later.
Here's the second side.
One strut done!
It actually fits and the holes line up. Woo hoo!
By the time I welded the fourth side piece, I think my welds got better. The line on the top was my last and I think my best. Just to be clear, I didn't say it was good, only that it was my best.
Here are my two struts ready for grinding and sanding.
Here they are after a little work. They still need more sanding but you get the idea.
I am really glad I decided to weld them myself. Even though the welds were far from perfect and far from pretty, I take a lot of pride in the fact I did it all myself.