just want some other fabricators to take a look and let me know if this appears to have enough structural integrity. i cut it so that i could half it together and it would then be all capped in. by the way i'm sorta back halving a blazer. this is one of the frame rails.
Looks like it would be strong enough to me. I would try to make that joint as tight as possible. Plating the joint would make it even stronger especially with the extra weight of the back of the blazer.
It will work fine as it is, but to make it stronger i would cut a diamond shaped piece of material to weld to each side of the joint, this ties everthing together solidly
looks too complicated, why not just miter cut it, bevel the edges, and weld it up? if you bevel the edges and weld it right, you can grind the welds down flat and not have a problem.....
i have started building a new frame for mine i have mitered the edges and drilled 3 1/2" holes in each end on both sides and plug welded flat bar inside the frame rails it is very strong