I spliced the broken pieces of square tubing back together with the 1-1/16" square steel rather easily. However the broken seam looked really bad so something had to be done. I got some 3" long aluminum angle pieces and machined them down to make cladding to cover the seam. To button everything together I used large rivets for a factory finish.
I also decided to go for the homerun by machining the small grooves into the cladding to match the appearance of the factory square tubing. All in all, the repair looks very factory like.
The ugly seam with the two pieces joined:
The cladding and the final appearance:
Total cost of repair was less than $15.00
Very happy with the final results.
