2 x 1 rectangular aluminum tubing?
 

I've heard that a lot of teams use this for their frame, and a couple of COTS things I saw seem to be designed for this. But a google search doesn't turn up this size, but usually 1/2 inch or something.

Where do I get this stuff and how much would it cost? What thickness do I need and what alloy?

Re: 2 x 1 rectangular aluminum tubing?
 

Re: 2 x 1 rectangular aluminum tubing?
 

http://www.wcproducts.net/versaframe

You can buy a whole array of stuff here. Other options exist as well.

Re: 2 x 1 rectangular aluminum tubing?
 

The holes and scribe lines are awesome but if you don't need them you can get it for cheaper at your local metal distributor.

Re: 2 x 1 rectangular aluminum tubing?
 

its a ripoff to buy most aluminum extrusion online.

Re: 2 x 1 rectangular aluminum tubing?
 

Here's some 2" x 1" tubing with a 0.125" wall thickness in a 6061-T6 alloy:

http://www.onlinemetals.com/merchant...268&top_cat=60

It's a bit thicker walled than the Vex stuff (good last year, maybe not this year) and about $4 per foot plus shipping.

Re: 2 x 1 rectangular aluminum tubing?
 

The best place to get the 1x2 tubing is from a metal distributor, as mentioned by others. We found one in our area a few years back and are paying about$2.25-2.50 per pound and get free freight delivery to a sponsor's location.

Do a quick google search and see what distributors are in your area; I found this one, but not sure the proximity to you.

For now, your best bet if you need it soon is to pay a bit more for it and order through online metals or look into the Versa Frame. The Versa Frame has a few unique things about it that may make more sense for some teams, pre-drilled holes and scribes to aid measurement/alignment on the 2" face.