pic: Chassis Idea

[Akash Rastogi]

Originally Posted by IndySam

We machine connectors (like 8020 quick frame) that slip inside the 1" square tube and then use Loctite Hysol to bond them together.

You can hit it with a sledge hammer and the aluminum will give way before the Hysol does.

This isn't that uncommon of a practice guys, and its fairly easy to do even with 1x1 and 1x2 square tubing. We've done it for the past 3 years or so; however, we machine out nylon and UHMW (and even solid aluminum) blocks to insert into the ends of the tubing. Then simply rivet, screw, or bolt the block into place. The ends of the blocks (or wherever you need) are drilled and tapped. The screw or large rivets are easily replaceable with hard epoxy, loctite, or even gorilla glue (in some areas). And there you have a snug fitting frame connector!