I need help figuring out why this weldment is so big compared to the others I've seen.
Usually, the profile encases the line segment, but in this case, the hug gaps are just incomprehensible.
It looks like your profile is 2.5 inch square and the tube length is only 30mm. I don't see anything wrong with that picture.
Peter Brinkhuis explained it nicely. I suspect you started this Part file with a template that was set to MMGS instead of IPS. You can change it from the drop-down at the lower right corner of your monitor, and then edit your sketch as needed.
Or embrace the change to SI units and join the light side
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