CPP notch problems with quality...round 2

[8mpg]

Just got the notch in today and while it looks like great penetration and teh outside welds look great, Im less than impressed. Im going to have to go back and weld the inside seams. There was a lack of penetration though the heat rings make it look like it was a good weld. Here are some pics:

Looks good from far:


Closer up, all you see is a gap between the pieces of steel:


Closer:


Here is the typical penetration for the whole thing...1/8" or so. The thing in my mind is about 1/2 welded and 1/2 as strong as it could be.


Anyone else have a problem with theirs? I sure wouldnt feel safe just bolting it on out of the box. To give them some credit...I just looked over it some more and some of the welds are nice and penetrate better than others, but definitely not 100% on the 1/4" steel. Im gonna say at most its 75% penetration on 30-40% of the welds.
THIS NEXT PART IS AFTER REPLIES FROM THE OTHER THREAD FROM CPP JEFF AND PEOPLE THAT THINK IM JUST CRAZY

Im not an engineer or professional welder...but they are just WRONG. Here is the proof. I did it and it still fits with TONS of room. What other vendors do has no bearing on a lack of quality on your product. This is simply bad welding job no matter how you look at it. Dont get me wrong, it fits great, good design, I like the product but the welding is something so simple and your engineers/sales dont care. You just say "it might look crappy...but just trust me, it works great" Why do new trucks have fully boxed frames that are hydroformed? Because frame strength is essential. Lots of engineering has come along since the 60's. For your "engineers" to say its not possible or you cannot weld the inside seem, is just laughable. No offense against you or the company. Im just another hobbyist that does think that proper welding and strength are important when Im gonna put my life in the hands of your work.

Moving on...

I welded the inside seams. Im not a professional welder and my welds are not as pretty. Simply MIG welded inside seams with teh welder set for 3/16 steel (so I dont melt through and mess up the pretty welds)




Good penetration:


Thickness of the weld bead that you guys say will interfere with the frame rail:


The impossible:


Still fits...both sides with plenty of room for a fatter weld.