80/20 aluminum extrusions as a body frame?

[hallotp]

Hi, I am trying to weigh all of the options of build, buy or convert, and wanted to see if anyone had an opinion of building a pod by framing with 80/20 and then skin with aluminum? The extrusion I am thinking of is the 1515 light weigh which is 1.03 lb per foot. Here is a link: http://www.8020.net/T-Slot-2.asp
If you are not familiar with it, it is super strong stuff, but I think that a frame would probably weigh in the 250-300 lb range. I thought of making the primary frame from it, but using 1x1 wood lengths to make up some of the cross members to support the skin.

Although this stuff is expensive, I have had good luck buying used lengths on Ebay for a good price, and I happen to have some of it laying around.
I was thinking that the pod would be built up similar to the WAZAT, and secured to a simple cargo trailer.
Any thoughts on whether or not this would be a good or bad idea?
Thanks in advance.

[John Foote]

That seems like a pretty expensive frame. The extrusions are one thing, but the connections are another significant expense entirely. 8020 swears that their connections never work loose, but the ongoing flexing and twisting of a trailer frame would represent the acid test of that claim. Failure of any one joint would be potentially ugly.

Welded and gusseted steel would be stronger, and probably lighter as well. I would guess that you could buy a halfway decent welder for the price difference.

I think you could find a better use for those extrusions you've got in slide outs and convertible mounts....

[Shadow Catcher]

The advantage is that it can be constructed with out welding, but will not be as strong.
I would think it would work but is going to be heavier than you need and a good bit more expensive. the MM uses 1x1.5X .060 tubing for the body frame and 2x3 for the trailer frame (I do not know the wall thickness). A tubular construction will be stronger for a given weight.
Aluminum can be welded using MIG or TIG

[Kevin & Sandy]

What size 80/20 will the frame rails be?

How will you attach the axle to this? Welding or bolting? I would hate to see something rattle loose !

I build frames for industrial machinery out of 80/20 but never thought about using it for a trailer frame. I have been thinking about using some 1010 and the delrin slides for sliding out a cabinet from the galley, though.

Kevin

[hallotp]

Thanks for the reality check. I think that you guys are right about the bolt together design being a bad idea. At first it seemed like an easy solution, but I can imagine a gradually loosening and vibrating frame destroying a lot of work. Back to planning!
Hal

[eamarquardt]

2BITS set the "standard" with the fabrication of his frame using 2 24' pieces fo 2X2 steel tubing. He wound up with 4" left over (but he could have lenghtened his toungue 4" and solved that, maybe).

I'm sure if you contact him he can provide pics (I can't remember the string).

Minimum cutting and welding. I'm a big proponent of making a custom frame. If you network I'm sure you can find someone with a chop saw and welder to help out. It would take a morning to fabricate a frame such as 2BITS made.

Much better quality, welded versus bolted, you can buy an axle with brakes, and you get exactly the dimensions you want.

Cheers,

Gus

[chorizon]

2BITS set the "standard" with the fabrication of his frame using 2 24' pieces fo 2X2 steel tubing. He wound up with 4" left over (but he could have lenghtened his toungue 4" and solved that, maybe).

Minimum cutting and welding. I'm a big proponent of making a custom frame. If you network I'm sure you can find someone with a chop saw and welder to help out. It would take a morning to fabricate a frame such as 2BITS made.

Here's a link to Thomas' (2bits) website.

I've looked at it before, and will spend the next hour or so reacquainting myself with his build. He did a great job!

The first few pics show what Gus was talking about...

http://www.grossepointegothic.com/LT/source/1.htm

[Woodstramp]

Ditto on the bum oppions on 80/20. We (have been forced to) use tons of it at work (industrial plant) by our engineering dept for machine guarding and some structural use. A light, quick guard...it's OK'ish. Structures...forget it.

It is expensive and inferior to welded steel. I literally curse something made with that junk at least once weekly. Our engineers love it because it whoops up easily in their CAD....but it's like that old saying about where something works well on paper, but not in reality. I love to see old 80/20 dumped in our metal scrap bins.

(Sorry for the rant...but 80/20 is a peave of mine...don't want to miss an op to rag on it.)