Quote:
Originally Posted by Nick5272
This is what Im thinking except Ill 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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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).