[RunninLo]

While the [I]legalities[I] can vary with the particular situation I would disagree with the idea that all frame welding isn't legal . If that we're true many of the custom coachbuilders that do limosuines and strech conversions would be out of a job. I know that commercial vehicle such as line-haul trucks and passenger busses have resrictions most personal vehicles are exempt. My experience has been to make sure the person operating the welder has a good backgroung in welding, not just practical but theory and metallurgy. If they don't know what a heat affected zone is... RUN the other way. Ask to see their AWS card and certs. Even the self taught boys off the farm can go to a local vo-tech and get certified if they're good enough. Remember it's not just your life but those of everyone in your vehicle AND those you pass by in other vehicles or passing by.

Now that I've preached a little how bout the tech. the angle of your cut isn't terribly important to strength but a straight up and down can make the move easier to measure and line up again. I know a few people have used angle cuts in a Z but it was not for strength but to slide the suspension forward as it went up... thus centering the wheel. neat idea for that reason but does nothing for strength.

The absolute best way regardless of how you cut it is to weld it correctly. Use only enough heat to get a smooth good penetrating weld. It is tempting for novice welders to crank up the heat because the bead "flows" a little easier and can give the appearance of a good weld. More heat = more heat affected zone, the area just outside of the bead that becomes brittle. Take a look at every "weld" that you have ever seen fail. It's not the weld bead ever but usually a crack or tear just alongside the bead. That is a result of heat affected zone. So just enough heat to get the job done . Then take a small plate ( i like the diamond look ) and weld over the top to add some strength and lessen the flex that will cause cracks.

As far as the guy at the inspection station.... well if you take your time and make everything clean and as close to a factory look as possible they probably won't even know what they're looking at. If you got bubble gum welds and zany cuts and jaggies everywhere.... slip a $50 under his coffee cup.

Josh