[Bryce2471]

Originally Posted by 42!

Have you ever used this technique in real life? Even if you have a facing cutter and a good size mill it would take a huge amount of time and resources. The same result could be achieved by bolting/riveting/epoxying/welding a reinforcement plate in the areas you need on some thinner wall tubing.

In general when working with square tubing it's a better use of resources to order a smaller size/wall thickness than to machine weight away from a thicker tube.

Yes, I have done this in real life. Admittedly to a tube smaller than the one pictured, but it did not take a lot of time or resources to do. Thinning the walls of the tube would be significantly stronger than bolting/riveting/epoxying/welding a reinforcement plate on, and would require less time and resources, because each side of the tube would have to be set up on a mill anyway.

Originally Posted by Chris is me

Could I get a picture of your shifter shaft without any gears on it? Kind of curious how that works out, with the pulleys on either end and the shifter in the middle.

Yeah... I wasn't able to come up with a solution that I really liked, but this is whats in the model:Picture