pic: Rough matches out there.

[BBray_T1296]

Originally Posted by JesseK

We tried to waterjet 4x2x0.125 tubing using PINK's method to only cut 1 side of the tube at a time, but the sponsor said they couldn't make it work on sample pieces. Luckily they had an in-house CNC and all it caused was 1.5 weeks of delay to get it done right.

We use an aluminum cutting circular saw blade on a miter saw to slice our tubing (I think it is a $120ish blade). We used 1x1x1/16" and 1x2x1/8" tubing to build our frame.
We also use some cool corner stiffener inserts to keep the whole thing square. Our tolerances come to 1/32" with our most experienced student at work. The welding gives us the most tolerance troubles, but we are less than 1/16" everywhere