I appreciate your concern, but it's welded. It looks better than the pic. Frickin' Auto flash.
It wasn't as bad a job as I thought it would be. Still, messy and overhead welding isn't my favorite position.
There are six points of attachment between the sidecar and the bike. I had four disconnected when this one let go. I'm thinking that this one ball stud had a small crack due to binding and I finished it by tilting the bike. I'm going to take this slow and easy for the foreseeable future but I think it will be fine.
My welders. L to R: Small generic inverter stick welder, Eastwood Tig 200-TIG and stick welder, almost invisible CH plasma cutter, Lincoln Weldpack 100 mig/gasless. Oxy set up is on the other side of the shop.
The Lincoln can handle up to 5/16" steel at 110 VAC using .35" flux-core wire, which is just about perfect for this job. It will only handle 14 ga steel using C25 and .30" solid wire. The little generic stick welder would have choked at this and I would have sworn at the 1/16" rods starting everywhere but where I wanted them to. I didn't have enough gas to do TIG and no filler wire. The big stick would have worked great but I prefer 7018 rod and only had a couple on hand.
I did consider drilling, tapping, and welding but wasn't sure that I could drill a straight enough hole by hand.