Sorry for the dark pics. The next step was to work out the attachment of the upper spars. I really want to cut into the square tube on the back of the head tube and 'sink' the ends of the spars into the sides of the square tubing but the more I looked at it and contemplated it I felt I was over thinking it and mated the diagonal up with the flat sides of the square tubing. The fit wasn't cut absolutely perfect mainly because of the next peice of the puzzle.
I wanted to put a cross tube between the two spars to tie them directly together. Don't ask me why, I'm not an engineer, I just felt it would add strength so I did it.
It involved cutting a hole through the protuding square tube. I wrecked my hole saw doing it but I got it done.
Then I took another piece of round tubing and fish mouthed it to fit snug up against the backside of the spar. This took almost an hour honestly. I started over at least once, it was a combination of two fish mount cuts and it was hard to place them in just the right place to get a good fit up. Later I repeated the fish mount cuts on the other end of the tube so the other spar would fit up snug.
I basically lost track of the pictures i was taking but at a certain I tacked the spars and cross tube in place with really heavy tacks and then used my ballpeen to form the ends of the cross tube tighter to top and bottom of the spars.
Here you can see the side gusset after I made cut out for it to fit snug up against the bottom of the spar.
Going to have to use some internet time lapse magic as I stopped taking pictures at one point so here it is welded up. A lot of what you see on top is multiple repasses to try to level out the top for aesthetics.
I also went ahead and seemed in the back of the spars. More gusset work to be done back here in the next post.