Aluminum U-channel

[theoldwizard1]

I have a repair project that I need to do this spring where I need about 4' of 2-1/4" (outside) aluminum U-channel. 2" is too small and 2-1/2" (which I already bought) is too large. The wall thickness needs be between .090 and .125

I don't own any welding equipment and likely would not try to weld anything like this anyway because it needs to decent finish (not perfect, but no "hump").

I can split my piece of 2-1/2" in half and then have it welded back together or start with 2 pieces of 2" angle and trim one side of each down to 1-1/8" and have that welded back together.

For you welders, which would you prefer to start with ?

 

[scoot86]

Why not get a piece of flat bar or plate bent in a break probably cheaper and easier

 

[theoldwizard1]

Why not get a piece of flat bar or plate bent in a break probably cheaper and easier

1) I don't own a brake

2) Some aluminum bends easily, some does not and can actually crack/break.

 

[PCustoms]

1) I don't own a brake

2) Some aluminum bends easily, some does not and can actually crack/break.

1) You don't own any welding equipment either but somehow that is your solution?
2) Pick the correct grade and this job is easy. Way easier then cutting and welding

how many feet of this material do you need?

 

[mike13u]

There is a 2.25 x .095 aluminum square tube in 6063. For only 4' all you would need to do is set your table saw fence up properly (account for blade kerf), put some wax on the blade, and rip the tube.
We make odd angles and channels like this sometimes when we cant find it. If you look at my Instagram link below, you will see us cutting a big 10" SQ tube to a 9x9" piece of angle for a client. Used a circular saw with clamped fence for that one but it's the same concept.

 

[bimmer1980]

I have a repair project that I need to do this spring where I need about 4' of 2-1/4" (outside) aluminum U-channel. 2" is too small and 2-1/2" (which I already bought) is too large. The wall thickness needs be between .090 and .125

I don't own any welding equipment and likely would not try to weld anything like this anyway because it needs to decent finish (not perfect, but no "hump").

I can split my piece of 2-1/2" in half and then have it welded back together or start with 2 pieces of 2" angle and trim one side of each down to 1-1/8" and have that welded back together.

For you welders, which would you prefer to start with ?

Why not rivet it together with a web plate? You didn't specify the application, so we are just guessing at options for you....

Remember that a weld in aluminum messes with the temper and can cause a weaker spot....

 

[theoldwizard1]

Why not rivet it together with a web plate? You didn't specify the application, so we are just guessing at options for you....

If I took 2 pieces of 2" angle and ripped down one side to about 1" I could put a plate across that short span to make it 2-1/4" but I would be concerned about the total thickness. Standard pop rivets would be out because of the required clearance on both side.

 

[theoldwizard1]

There is a 2.25 x .095 aluminum square tube in 6063.

Why is it that you are the only place in the entire US that is selling 2.25 square tube ?