Tubing 1.500 x.095 Round ALL22138-4

OVERVIEW

When you''re building a custom Baja Bug or a hardcore Sand Rail, the foundation of your safety and structural integrity lies in the quality of your steel. The Allstar Performance 1.500-inch x .095-inch Round Tubing is a staple in the air-cooled VW community for a reason. This specific diameter is the "sweet spot" for building lightweight yet incredibly strong roll cages, nerf bars, and engine cages that can withstand the brutal vibrations of the dunes or the rocky trails of the desert. At Appletree Automotive, we understand that your project depends on precision, and this mild steel tubing offers the perfect balance of weldability and formability, ensuring that your custom chassis components stay exactly where you put them, even under extreme stress. It is the go-to choice for builders who demand a professional finish on their structural fabrication.

High-quality fabrication requires materials that aren''t just "good enough," but are engineered to meet the demands of off-road racing and custom street builds. This 4-foot section of Allstar tubing is ideal for those smaller bracing jobs, shock mounts, steering column supports, or bumper repairs where a full stick is overkill. The .095-inch wall thickness is a favorite among VW builders because it provides significant torsional rigidity without the excessive weight of heavier .120-wall pipe, allowing your Beetle or Ghia to maintain a better power-to-weight ratio. Whether you are tying your shock towers together or crafting a custom light bar for your off-road machine, this tubing delivers a clean finish that takes paint or powder coat beautifully once prepped correctly. Don''t compromise on your chassis; use the steel that professional fabricators trust.

FITMENT

This is a universal fabrication component commonly used for structural and aesthetic upgrades on the following air-cooled VW based vehicles:

• Volkswagen Beetle: Ideal for Baja Bug roll cages, engine cages, and nerf bars.
• Volkswagen Karmann Ghia: Perfect for custom chassis stiffening and internal bracing.
• Volkswagen Bus (Type 2): Used for custom roof racks and interior structural supports.
• Volkswagen Type 3: Great for custom suspension mounting points and reinforcements.
• Volkswagen Thing (Type 181): Excellent for perimeter cages and brush guards.
• Sand Rails & Dune Buggies: The industry standard for chassis bracing and component mounting.
• Meyers Manx & Clones: Used for roll bar fabrication and rear cage assemblies.

SPECS

• Outer Diameter (OD): 1.500 Inches
• Wall Thickness: .095 Inches
• Material: High-Quality Mild Steel
• Profile: Round Tubing
• Length: 4 Feet (48 Inches)
• Finish: Raw Steel (Requires prep before coating)
• Weight: Approximately 1.42 lbs per foot
• Part Number: ALL22138-4
• Manufacturer: Allstar Performance

PRO TIPS

1. Master the Art of the Fish-Mouth Notch

When welding 1.500-inch tubing into a chassis, your strength is only as good as your fitment. Never rely on a large weld bead to fill gaps. Use a dedicated tubing notcher or a high-quality hole saw to create a "fish-mouth" joint. This ensures the tubing wraps perfectly around the mating surface, providing maximum surface area for the weld. A tight, gap-free fitment significantly reduces the heat-affected zone and prevents the tubing from warping during the cooling process, which is critical for maintaining the geometry of a VW front beam or rear torsion housing.

2. Prep Your Surfaces for Penetration

Mild steel tubing from the mill comes with a layer of "mill scale," which is a dark, flaky coating. Welding over this scale leads to porosity and weak joints. Before you strike an arc, use a flap disc or a wire wheel to grind the area back to shiny, bare metal. You should clean at least one inch away from the weld zone. Additionally, since this is a 4-foot section, ensure you wipe the entire piece down with an oil-free degreaser like acetone before painting or powder coating to ensure the finish bonds permanently to the steel.

3. Account for Spring-Back When Bending

If you are using a manual or hydraulic tube bender, remember that .095-wall tubing has a specific "spring-back" rate. When you hit your target angle on the degree wheel, the tube will naturally relax a few degrees once pressure is released. Always test a scrap piece of this specific Allstar tubing first to see how much it springs back. Typically, you might need to over-bend by 2 to 4 degrees to achieve a perfect 90-degree corner. Using a high-quality 1.5-inch die with the correct radius will prevent the tubing from kinking or flattening during the bend, maintaining its structural integrity.