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Originally Posted by JesseK
Foot for foot, 80/20 aluminum isn't that much heavier than 1x1x0.0625-wall extrusion. The biggest weight difference is in the fasteners --
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I will say that it is good metal, and easy to work with, but the only problem that we ran into was how heavy it is, because the (1"x1") weighs about a pound a foot.
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I do not mean to be rude and correct you guys, but I know from many years of working with these materials that 1"x1" 80/20 Alum is 24.6" per lb. Where as 1"x1"x.0625 wall Alum extrusion is 48" per lb.
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Phenolic materials are durable, easily machined, have great mechanical properties, and cheap.
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I also want to warn anyone who is machining phenolic that the dust created by machining it is very toxic to your lungs if you breath it in.