Fabbing a custom awning

[gloveman132]

Hey guys,

I am going to fab a custom awning for the door of my shop. The awning will probably be 6 feet wide, three feet deep with about a 30 degree slope.

Since I live on the coast I will use one inch stainless steel square for the frame.

What thickness square do you recommend?

Thanks

 

[mike13u]

Depending on how severe your weather conditions are, you could probably do 1.25" x
.0625" square tube for the frame. Maybe even 1". What will you use as the covering?
I would rethink the stainless. Maybe see what a powder coater would charge you to weather proof steel. Stainless is just too pricey now. Steel will run you about 1/3 the cost of steel and a good enamel paint (think tractor/machinery paint) will withstand the elements. Stainless could be triple the cost of steel depending on the grade.
Do you have the means to weld aluminum? You would be much better served with aluminum from a strength, weight, and durability standpoint. Not to mention costs. Also, aluminum will work better if you are on the coast and the environment is salty. Most awning frames around here are aluminum. Im near the coast and in hurricane epicenter.

 

[gloveman132]

Thanks Mike13u,

I am just up the road from you in Melbourne. The awning will be finished in Sunbrella canvas.

Powder coat concerns me because I have nightmares of rust stains streaming down my walls.

If I go aluminum, what size square tube do you recommend?

 

[55shoebox]

Almost all awnings like that are made of aluminum - 1" square .065 - .090 wall light strong and will hold up well. They even make alum extrusion that will accept the edge retainer for the sunbrella. Look at sign supply places - you might even find a sign shop they almost always have old awnings laying around find a section you like and re-cover it. I was in the sign buisiness a long time and sold a lot of the frames to people to re-use.

 

[Nor*Cal]

My dad owns an awning shop. 1" square .065 steel is standard. Though some designs use round. Aluminum is too expensive for most customers and needs to be thicker than .065. We Powder coat everything, holds up better in this application. 55shoebox, I think is alluding to extruded aluminum awning rail which can be found online. We use that, rivet it to the back of the top rail and sew cord into the top of the sunbrella cover. There are also Z-clips that make hanging the awning easier as opposed to finding the studs, then figuring out where to drill through the awning frame.

Also, the biggest force on the awning will be uplift during a wind storm so fasten the bottom legs or returns. Also, silicone the holes you drill into the wall prior to fastening and silicone the top rail, this will prevent water penetration.

Awning Rail:

Z-Clips:

Attached a crappy profile done in MS paint as I don't have access to the CAD files at home. Let me know if you need any help. I grew up welding, sewing and installing fabric and metal awnings.

 

[Nor*Cal]

Just caught the stainless part. We have done a few blade type (no side fabric) in polished stainless. They look great.

How did you plan to attach the fabric? Lace it on with rope or use small screws to attach it? With the small screw we would sew a small pocket along the perimeter and put 12-gauge hanger wire in the pocket. That will allow you to tension the fabric and use screws to hold the tension without ripping through.

 

[gloveman132]

Thank you everyone for the most helpful replies.

Now that I know about the awning rail, I will run that along the top as suggested.

For attaching the bottom portion I am planning to weld in a rail like the one pictured below. This shot is of a new awning I saw going up last week.