I recently, impulsively bought an Incra CleanSweep router enclosure, thinking it would be a miracle cure after twenty years of laboriously vacuuming up messes underneath my router table after every use. No doubt it will work great and be worth every penny, but I realized only after the fact that it's not compatible with my existing shop-made router table due to its form factor and the presence of the collection hose. Ergo, I now need to build a new router table base. I could just do this out of MDF and solid wood, like my existing one, and that would be totally fine. But I'm intrigued by the idea of using 80/20 aluminum components to construct the frame--partly for the coolness factor and also by way of learning a different way of doing things. I realize Incra and others sell router table packages, but I'm not interested in that, as I want to keep the Woodpeckers tabletop and lift and Benchdog fence that I have, which work great.
So my question: Has anyone built a router table, or something similar, out of 80/20? What profiles/dimensions and components did you use? Is there any issue of rigidity or racking?