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We're making a 4 stage telescopic arm. The base is 5x5 aluminum square tubing, the next stage is 4x4, then 3x3 and 2x2. I'd suggest searching for images of telehandlers for inspiration. JLG, Genie, and several others make a lot of machines like this. Your local Sunbelt or United rental may even let you analyze one up close.
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