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Obviously the KISS rule applies. LOL
But on the other hand you can make more exhaust room the other way.
How is the exhaust gonna go? Under the car or around it?

 

I'd do the one on the right myself. Cap the end, then weld fish plates over where the two meet. Super strong and clean.

 

What Tony said

 

i could be wrong but i believe a fish plate is a plate going from one piece to the next. Layed on top over the gap between the 2 pieces. Usually seen them diamond shapped. Haha I googled it to find a pic......and ended up with plates of fish .

 

That was meant to be tongue in cheek. Maybe I'm not gettin' it though.
It seems that no matter what you do if the crossmember has to be at 90* to the frame rails and has to have a drop,it either has to be bent or have 2-45's on each side that have to be capped if it's put together in peices.
On the other hand you could just use 45* pie cuts and bend it and have no end caps.
As far as strength goes it's prolly 6 of 1 half dozen of the other if it's welded well.
I'd prolly go for the pie cut version as opposed to either version in your pics strictly for aesthetics sake because when you look under the car you don't have to look at the end caps that way.

 

I looks to me that you have the same thing, except one has two angles and the other has only one. The fish plate should cover the straight welds with a oval shaped piece. Remember that the weakest point is the parent metal about an inch away from the weld. Assuming you have good welds.

 

why do you want to cut it and have open ends you need to cap? either way you have pictured is extra work.

think about it for a minute. don't make me have to come back and draw a picture.

 

If you take the time to figure out the angles you can but weld them together and have no open ends to cap. This method will result in a stronger crossmember.

 

What he said.

 

I'd miter them, if you want to get fancy you can pie cut them where you need the bends and then bend it into it's final configuration - if your tubing is long enough - if not plain old simle miter cuts makes it easier than having to go back and cap the ends IMHO. Just thinking out loud.

 

That's not a bad idea, BUT, you could mitre the angles into the tubing giving you the same 45 you wanted..Then weld them together at those angles. By doing that, both the side tube's and lower tube will be able to be welded at the 'open' ends so no cap's would have to be made..

Edit..
I type to slow..HemiRambler said exactly what i was trying to type..but better
haha

 

Just 45 it or what ever degrees it needs. You're making a lost of work.

 

no. you still have open ends.

 

what he said she said ?

 

go look at a picture frame ! or all the wood trim in your house.

 

You could also do something like this with 22.5degr cuts. In my mind it would look a little more flowing and nicer than squared as per your last drawing. If I'm not mistaken it should also be a bit stronger too, meaning that there should be less side to side flex.

 

What he said is what I meant earlier. I just forgot to divide the 45's by 2.

 

there's neophyte with the picture I didn't want to have to draw.