I know this is a kind of no brainer question for a welder, however I was wondering the best and most economical and possibly cleanest way to put an endcap on a square tube. I have included a link for a pic of the tube assembly. I know I could weld the cap in the pic onto the square tube, but you would see a weld joint around the part. I have seen 3d images of endcaps that are flush with all sides, but not sure how they could weld this without seeing a beed around the edges. The part in question is a 1.5" square tube, so could I just use a 1.5" square cap? what kind of weld joint would this be, and how would you make it look like there is no weld after....sand it?? or could you just insert a smaller cap into the hole through the tube to sit flush with the end of the tube and solder??
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