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Barry Blitz
02-15-2021, 1:16 PM
I want to be able to clamp against a flat reference. I will be clamping 2 or 3 plywood strips of 3/4" thickness. The only 4" width product available to me is a 2" x 4" that is 1/8" in wall thickness. Is this sufficient?
Steve Rozmiarek
02-15-2021, 2:22 PM
Yes a 2x4x1/8 tube of aluminum should be stiff enough to not deflect. It'll obviously be stiffer the 4" dimension.
Barry Blitz
02-15-2021, 2:30 PM
Yes a 2x4x1/8 tube of aluminum should be stiff enough to not deflect. It'll obviously be stiffer the 4" dimension.

I want 4x4 1/4", but it's only available uncut at 24 feet. $320. So...., no.
ChrisA Edwards
02-15-2021, 2:38 PM
https://www.mcmaster.com/aluminum/shape~rectangular-tube/outside-height~4/outside-width~4/wall-thickness~1-4/
Doug Garson
02-15-2021, 2:46 PM
Why aluminum, wouldn't steel tube be cheaper for comparable strength? What length?
Barry Blitz
02-15-2021, 3:07 PM
Why aluminum, wouldn't steel tube be cheaper for comparable strength? What length?

6' stretcher and leg construction for tables, workbench, general clamping.
Steve Rozmiarek
02-16-2021, 8:52 AM
I want 4x4 1/4", but it's only available uncut at 24 feet. $320. So...., no.

That would be a nice piece of aluminum to have around though, someday it might even all get used!
Barry Blitz
02-16-2021, 2:11 PM
Steel would be heavy, and maybe even rust in my garage.
ChrisA Edwards
02-16-2021, 2:32 PM
I needed something like the OP, a couple of months ago, while I was laminating some Baltic Birch to make front and rear fences for a new cross cut sled.

About 2 years ago, I replaced the fence system on my SawStop for an Incra setup.

I remembered I had the long rectangular front tube rail, from the Sawstop fence, it was perfect to clamp to.
Doug Garson
02-16-2021, 4:57 PM
Steel would be heavy, and maybe even rust in my garage.
A quick coat of rattle can paint should avoid the rust issue but the weight could be an issue.
Bill Dufour
02-17-2021, 5:17 AM
Location? and words to make the count
Jay Rasmussen
02-17-2021, 8:10 PM
Have you looked at 8020? They have a lot of options for structural shapes.
Ben Grefe
02-17-2021, 9:02 PM
Interesting I've learned that 8020 aluminum extrusion is *not* straight. I got a bunch of it for my Avid CNC and found that rails will have a slight bow in them. I wouldn't trust one to be used as a straight edge by default.