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Old 03-27-2023, 10:34 AM   #1
Skoolie
 
Join Date: Dec 2022
Location: Greenville, SC
Posts: 130
Year: 1991
Coachwork: Bluebird
Chassis: TC2000
Engine: Cummins 5.9
Quick Question On Sizing

Hey friends, I am headed to buy the square tubing for framing my RV windows in the hat channels.

My options here are:
1/16” thick 1.5” square tubing
1/8” thick 1.5” square tubing
1/16” thick 2” square tubing
1/8” thick 2” square tubing

Please help me decide. Thank you!

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Old 03-27-2023, 10:50 AM   #2
Bus Crazy
 
Join Date: Oct 2020
Location: Near Flagstaff AZ
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Year: 1974
Coachwork: Crown
Chassis: "Atomic"
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Funny, but none of those sizes seem to match what I use most. I'm not sure what you mean by "framing windows in the hat channels" so let me tell you what I usually find. I find that 1" (I get thick wall) square tube fits inside lots of hat channels. But for other framing, I seem to use a lot of 1.25" square tube. And sometimes, 1.5" inch. It all depends upon the existing wall thickness, which I need to measure on each bus. I've never found one that needs 2", though.
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Old 03-27-2023, 12:24 PM   #3
Skoolie
 
Join Date: Dec 2022
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Year: 1991
Coachwork: Bluebird
Chassis: TC2000
Engine: Cummins 5.9
That’s very helpful. I’ll bring a hat channel extension with me to the metal yard today and see what seems like it may fit
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Old 03-27-2023, 12:53 PM   #4
Bus Crazy
 
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Quote:
Originally Posted by Nick5272 View Post
That’s very helpful. I’ll bring a hat channel extension with me to the metal yard today and see what seems like it may fit
For framing around windows, like RV windows, I don't use hat channel. I use square tube. I am admittedly not clear on your plan, but for lots of buses I've done the window framing was 1.25" square tube
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Old 03-27-2023, 01:33 PM   #5
Skoolie
 
Join Date: Dec 2022
Location: Greenville, SC
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Year: 1991
Coachwork: Bluebird
Chassis: TC2000
Engine: Cummins 5.9
This is what I’m thinking except I’ll extend it all the way to butt up against the next hat channel and be welded or bolted there
https://imgur.com/a/Afgwghj
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Old 03-27-2023, 06:37 PM   #6
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Quote:
Originally Posted by Nick5272 View Post
This is what I’m thinking except I’ll extend it all the way to butt up against the next hat channel and be welded or bolted there
https://imgur.com/a/Afgwghj
Seems like you would want material that was the same thickness as the hat channel. If I'm not mistaken, Blue Bird hat channel is 2" deep so 2" square tubing would work best. The strength difference between 1/8" and 1/16" will be pretty irrelevant but the 1/8" thick tubing would be easier to weld without burning through the material; 1/16" would of course be cheaper (especially since you already have it, going by your reddit post).

Remember to wear a respirator when welding galvanized (or even when welding non-galvanized).
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