[Allison]

Thanks for the interest in our design style.

1. We use 1" O.D. .065 wall 6061-T6 aluminum with a 3" radius for all of our bent tube. We have tried to bend .035 wall tube but it kinks.

2. All of our bending is done with a manual draw bender.

3. We uses a couple different types of fastening methods. Tube connector nuts pressed into the end of the tube is our main method, they can be purchased from McMaster 94290A550. We also use u bolts, rivets, through bolt, and custom FDM parts.

4. Typically we measure our bends with a printed 1:1 layout of the design and match it. We normally cut the tubes after they are bent as to not worry about OAL. If a tube as multiple bends we do one bend then measure for the next location. Tube is very forgiving if you over bend or under bend you can usually adjust the tube slightly by pushing or pulling on in. If hole locations are critical they are drilled after bending.

5. Round tube works very well for 1024 but it is not for everyone. The main advantage is strength to weight ratio. For us structures are easier to make out bent tube because we can typically make them simpler and with fewer parts compared to square which requires mechanically fastened joints or welding.

6. I will look and see what I can find.

1024 is open to answering any additional questions you may have. I will keep an eye on this thread.

Allison