Beginner resources for working with extruded aluminum profiles?

[Ernie Mccracken]

Are there any good videos or other resources available on extruded aluminum? I've never worked with it before, would like to, but it is a bit overwhelming.

Some things I'm thinking about as someone with no exposure:

• What is the difference between the brand name 80/20 that is unholy expensive and generic import brands?
• How do I cut it cleanly and millimeter perfect, like what's needed for a stand? What tools and techniques do I need?
• How do I calculate maximum safe load?
• Basic joinery, at least basic 90° and 45° intersections
• How do you make doors?
• How do you make skins?
• What software tools are available to help with modeling, cut lists, hardware list, etc.?
• This ain't $5 cinder blocks and 2x4's, any tips to not overspend like crazy?

 

[Justfebreezeit]

Most of the websites you can message or call and tell them the size and purpose and they will send you a quote and drawing

 

[Initialr]

I would suggest watching a bunch of videos on YT and compare stands that are already pre-made to use as a blueprint. This was how I gathered all my info to design and order my stand. There are tank builds on R2R that use aluminum ext that you can also look at.
Alufab is a company that works with Tidal Gardens and has a bunch of pre-made kits you can purchase or use as a blueprint.
Using alufab's standard stand for a 120, I added two more legs (total 6) and an extra cross bar at the base to over build my stand. 45 degree cuts you can have them cut for you or diy.
joinery wise- everywhere I read the best is to have anchored attachments, where there is a center bore for the anchor and the tnut is at the attachment end.
Doors- you can use hinges that attach on one side into the grove with a tnut and the other onto the door or just french cleat and do panels.
Software- I'm sure there are a bunch, I did play with one I found online, but it was just easier for me to pen & paper. I did find another program that might help you- https://us.misumi-ec.com/service/promotion/frames/

Not sure if there's a difference with 80/20 vs generic brand, but I would stay away from anything labeled "Light Weight", they generally have the same design but the walls and center are not as thick and do not have the same strength for obvious reasons.

By no means am I an expert now, but I know enough to order my stand from scratch from my research.

 

[AudioJunkie]

No clue on best methods for cutting as I had everything cut by 80/20.

I designed my stand in their IdeaBuilder online program and loaded the cart with the BOM it generates from the design.

IdeaBuilder

They also have a load calculator, lots of videos and PDF’s of the different products they offer and how to implement them.

I emailed them a lot of questions in my design process and they are very helpful and responsive.

 

[areefer01]

If you like to dabble and learn new things 80/20 is fine. You will soon learn that quality is important especially with fittings.

If you are capable of following instructions, have some basic wood working tools, I recommend reading Rocket Engineers tank stand thread here and on Reef Central (archive). Plenty of hobbyist have used this to build everything from a 40 breeder to monster stands supporting 475 gallons.

If you are trying to build a stand I would encourage you to reach out to a local fabrication shop and get a quote for both steel and aluminum. You may be surprised on the cost.

Allufab was mentioned and they are easy enough to get a quote. It will be spendy and in some cases more expense than the display sitting on it. Shipping is extra.

If you are having a semi custom tank ask them to include a stand as an additional line item quote. Since shipping is included, or extra, the stand will typically be at its cost. Not an additional shipping cost.