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Hmmm, precision is probably not my forte. Just welding the headtube extension and bb boom joint might be easiest eh? Interested to see what you did at the bottom of the headtube extension, did you bother with a bottom headset cup?
M_V-
Here we go. My hacked kona cargo thing...
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Yep, welded the bottom headset cup into the bottom of the headtube extension. I cut a steerer out of an old knackered suspension fork then welded this onto a long piece of 1 1/8 pipe to make a mega steerer. This meant I could put the crown race on properly at the bottom.
The first iteration snapped at the key join between headutbe and cargo base when carrying two small children across a park. No damage to the children, but I had to beef up this joint with the brace you can see in the box. Been good since.
The front end is a kids BMX headtube, fork and wheel. I got it out of a skip but these bits were still serviceable so the angle grinder was employed to part it out.
It's flexy as a flexy thing when loaded, but handles the weekly shop or one small child fine. It's best for going to the tip at lunchtime on a weekend. Everyone else queuing in their cars while I slide straight in fully loaded. Some are amused, others clearly fuming.
I'm surprised my welds have held up as well as they have, but I give it a good bounce and visual inspection every month or so. It lives outside in the rain and the cold so it's doing pretty well all things considered.
Scrabble
Hmmm if you think you can get the tolerances right and it will be stiff enough, go for it.
I found the whole experience I bit like using a glue gun on metal. I was very much working in a measure once cut twice kind of vibe.
Head tube extension was the first thing I did and was probably my best weld...Pics to follow.