pic: Rastogi 8wd Iteration 1.2

[artdutra04]

Originally Posted by 548swimmer

6061 T6 is crazy strong, and really expensive. Depending on where/how you guys machine you might look at a 50XX series alloy with a lower temper (T).

It sounds like you've confused 6061 with either 2024/7075/7068. These are all much better than 6061 or 5052 in regards to hardness and yield strength. But like 6061, they need large bend radii and are thus unusable for many sheet metal components (which you are correct in that they're traditionally 5052).

If you have good suppliers and know where to look, small quantities (such as for personal project or a FRC team) of 6061 aluminum stock can be bought for as little as $1.50/lb. I bought a 15 pound bar of 6061 last year for about $25. I've also found 3/8" Hex bar made out of 2011 aluminum (easy to machine grade) for about $0.50/ft, which our team then promptly bought all 60 feet they had in stock for custom standoffs for the next few seasons.