How hard is it to weld 80/20 extrusions? Is it worth welding or is it better to just use the brackets?
I’ve never tried welding 80/20, but I would imagine it would take longer and possibly be less structurally sound than using the hardware that’s already available for the same purpose.
The beauty of 80/20 (Aluminum t-slotted extrusion) is that it is made to be extremely customizable and modular. Many advantages you gain by using t-slotted framing are lost if you decide to weld the sections.
If you want to have Aluminum welded together you are probably better-off using regular Aluminum tube stock (it’ll be much cheaper).
Something to consider if you do choose to weld Aluminum t-slotted framing: it will most likely be anodized (even if it’s silver, it’s most likely clear anodized). In order to weld, you need to get past the anodized surfaces to properly weld the Aluminum