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Originally Posted by Monochron
Maybe I am undervaluing the usefulness of that hole pattern, if so could someone enlighten me? I see it as something that can save you some measuring when trying to line things up, but can also cause you to waste time cutting the tubing so the holes line up perfectly
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It's really easy to do this. We just made a little jig that anyone with a CNC mill, 3D printer, router, or any number of machines could make. A little flat plate 2" long, 1" wide, with two hole-sized nubs sticking out of it 1" apart. Just place this in your VersaFrame part and mark the piece at the edge of the jig. If you can't make this jig, just use a VersaChassis gusset, a few (non-installed!) rivets, and a steady hand to do the same thing.
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and can make mounting near a hole a serious pain as it ruins the strength of the metal at that point.
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This really isn't the case at all. A hole less than 1/4" in diameter is going to have minimal impact on a beam's resistance to bending, especially since the hole is not on the face normal to the hole. There is no noticeable difference in strength, certainly not even close to "ruining" the part.