Excalibur ‘09

As seen in the photo above i already had a 1/4" screw protruding from the upper section from when i first installed a LED light. So i cut a 3/16" thick steel disk and soldiered it into the bell shaped lower section. A nut through the center hole trapped both sections together. Then soldiered both halfs together, sloppy, crude and ugly, but strong!

I had previously made little 1/16" thick reenforcement straps that had vibrated apart that that is the likely cause for the failure in the fist place. This time i'm using 1/8" thick 4130 and larger radii in the corners. Good enough for Nascar roll-cages and aircraft structure, then good enough for me!

All done and imma on the road again, hopefully it will last another 6500 miles or more!

Of course until then i'm just waiting for the next tbd weakest link to shake apart! LOL!