Hi Burr,

> Does anybody else envision a weld bead as this shape?

I just Googled Images for 'tube weld' and got these.........

http://www.bikesportmichigan.com/reviews/blade05/lg/bladeseatmast.JPG

http://gallery.mtbr.com/data/mtbr/515/234452TiHeadTubeWelds1.JPG

http://www.penguincycles.com/fab/fab_weld1.JPG

Closer to a constant fillet, I think :)

[EDIT] Or this beauty........ http://dana60.com/sceep/sob/booger4.jpg ......model that!!!


Cheers
~Danny~