I cut the short 3/8 x .090 tubes for the hinge feet. Then I drilled the center out for a 3/16" bolt. I cleaned up the tube ends then welded them to the washer to make the feet. To keep it straight I clamped it together with a nut and bolt. The first one turned out fine but the second one was crooked. I found stacking it on a drill bit stacked washer to washer with the finished one worked better and keep it straight.
After tack welding the final weld was made. I managed to burn through the washer on the first one so I scraped it. I actually filled it with rod and it came out okay but I decided to use it as practice. I managed to make one more into scrap when I welded it with the nut and bolt still on it. I couldn't get the bolt out after that - it was a good weld though :-)
Next I did the 7/16 x .090 tubes then drilled them out to 1/4". I made some new washers with a 1/4" hole. Then I welded the tube and washer together. For these it worked fine just to stack them up on a 1/4" bolt with the washer against the head (no nut) and tack weld them.
I managed to make the 1" feet to long. I didn't notice that the measurement is from the other side of the washer (different than the shorter feet). So I use the bench grinder to shorten them.
3/23/08 - Added Note: If I were to do it again I would have left these tubes 1" or even a little longer then sand them down after welding. It was difficult to get the bead around the "V" between the arm and the tube without cutting into the bolt seat surface.
