Used to work for a fellow that was a well known chassis builder and very safety concious. Here are a couple frame splicing tips I picked up: frames are designed to flex so never box a short section of "C" channel frame, this will make that section rigid and set up stress points that will crack at each end of the boxing plate. Next, don't use plate that is grossly thicker than the frame itself--same reason. The diamond shape reinforcing plate is preferred with a hole halfway between the point of the diamond and the part thats over the splice so it can be rosette welded. This prevents humping or twisting in the area between the perimeter welds. Taper edges of the frame joint so you can get 100% penetration without excessive heat from your weld. Now I just wish I had paid closer attention to anti-dive and Ackerman angle from a master but a teenage kid has other things on his mind, especially if it's in tight jeans.
