While people are hunting I've been having a hell of a time finding some 7/8" tubing with rounded corners so if you happen to spot some of that please post it up.
Despite picture, says is .125" wall. Is from 80/20 catalog and meant for ladders, guess that's why the round edges. Is only 48" long, but they have an 8 footer on offer as well. Might be able to just contact 8020.net and buy direct.
Check the Alro in Ann Arbor, Michigan. If they have it listed in stock, let me know. Its literally on the same block as my job. I can stop and take a pic
Haven't found it in 6061, but found it in 6005 which I think will be okay.
I don't think I'll find 1" x 1" square tubing with the ( larger) radius like the OEM frame.
I might find 2" x 1" with the correct radius and cut it in half to fit, but it would probably have only 1/2 the strength of a full square tube. Also don't know if it could be shaped with a die.
So, just trying to decide which way to go. Will also look for the 2" x 1" x 1/8" rounded edge square tubing.
That's a big radius, are you sure? The round over & ball nose mill ends I use are 0.250" radius, here's what an exactly 1" wide channel cut with a 0.250" radius looks like.
There's only 0.500" of flat between the curves. At that point, they might as well just use round tube, because the joints are gonna need special miters anyhow. I'd bet the radius on your tubing is closer to 0.125" (or less), leaving 0.750" (or more) of flat. For a 0.125" wall, you could do straight cuts and fill the gaps with weld easy.
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