A fella I do work for once in a while brought me a project. It's a brass "X" frame that supports thin legs on a heavy wood cabinet of some type. It's made from (approx) 1/2X 1.5 rect. bar with 35mmX1.5MM rings that slip over each wood leg. The X connection is cut as slots 1/2 way through each member with a small machine screw holding the bars together where they cross. I think each bar is 6' long. The plan was to just silver the rings on the end but there is a lot of the ring touching the tooling which is aluminum.

The guy is an impressive fabricator but something went wrong and one, if not both of bars are a bit too short. The one I looked closely is about 3mm short (we are talking overall length, the way that matters). He asked me if I could use weld to make it longer. I am also doubting it will be able to support itself not welded (silver brazed) in the middle. I didn't have time to measure for sagging.

He brought it to me offset about 2" from an high density wood particle sheet on turned "offsets" under the end rings.


Anyway, what are my chances when it comes to surfacing the end of the brass bar? I know TIG won't work. It seems like it's going to be very difficult to do that much build up on the end of the brass bar with a torch. Making thicker/larger OD rings is off the table.

oh, and the legs are already on the piece which is not even in the same state as the brass.

I have a few days before again speaking to the decision maker and I hope that those in the know might share some info and shorten my journey to customer satisfaction. I have several gas torch sets and I have nice nickle bronze alloy rod and some generic yellow brass filler (with flux on).

The bars are brass, not silicon bronze

Thanks, Frank