Reinforcement tube split A 1 1 /2 A 1 1 /2 A Weld 30° 30° Weld Dented or bent tube Cracked tube A 1 /2 A 1 /2 A A A Replacement tube 30° Original tube Inside sleeve tube 3 /4 A Rosette weld 1 /8 "  gap for weldings 5-33 Figure 5-48.  Splicing with inner sleeve method. Figure 5-47.  Repair using welded sleeve. Tube Splicing with Outer Split Sleeve  Reinforcement Tube Splicing with Inside Sleeve Reinforcement To perform the outer sleeve repair, remove the damaged  section of the tube, utilizing a 90° cut at either end. Cut a  replacement steel tube of the same material, diameter, and  at least the same wall thickness to match the length of the  removed portion of the damaged tube. The replacement  tube must bear against the stubs of the original tube with  a tolerance of ± 1 ⁄ 64 -inch. The material selected for the  outer sleeve must be of the same material and at least the  same wall thickness as the original tube. The clearance  between the inside diameter of the sleeve and the outside  Make a diagonal cut to remove the damaged section of the  tube, and remove the burrs from the inner and outer cut edges  with a file or similar means. Diagonally cut a replacement  steel tube of the same material, diameter, and wall thickness  to match the length of the removed section of the damaged  tube. The replacement tube should allow a  1 ⁄ 8 -inch gap for  welding at each end to the stubs of the original tube.  Select a length of steel tubing of the same material and at  least the same wall thickness with an outside diameter equal  to the inside diameter of the damaged tube. From this inner  sleeve tube material, cut two sections of tubing, each of  such a length that the ends of the inner sleeve is a minimum  distance of 1½ times the tube diameter from the nearest end of  the diagonal cut. Tack the outer and inner replacement tubes  using rosette welds. Weld the inner sleeve to the tube stubs  through the  1 ⁄ 8 -inch gap forming a weld bead over the gap  and joining with the new replacement section.  [Figure 5-48] If a partial replacement of the tube is necessary, do an  inner sleeve splice, especially where you want a smooth  tube surface. If partial replacement of a damaged tube is necessary, make  the outer sleeve splice using a replacement tube of the same  diameter and material.  [Figures 5-49  and  5-50] damaged area of the tube. Weld the reinforcement sleeve  along the length of the two sides, and weld both ends of the  sleeve to the damaged tube. 