Uh, I plugged in the wrong value for (n) there are 8 welds, not 4, so weld length L1=1.96"
sounds a lot more reasonable?
I have a couple more questions...
is L1 a maximum length?
and where does it show the size of the plates that they weld the bar to, I'm assuming that the area of the plates should exceed the area of the bars. I see in welder qual they give the plate width as bar diameter +1", but for WPS, where is thickness?