El Beast - Initial design phase, comments and critique welcomed!

[Zeeflyboy]

I thought about that, and I may yet do so... The problem I'm thinking is that it really helps me out if these are perfectly matched length wise. Given that I'm sure they set the cutting length and then chopped one after the other, when done as a pair they should be pretty much spot on. If they send me a single one to replace the dinged piece then there is no guarantee that it will be as closely matched and will be subject to their cutting tolerance instead (which they don't actually seem to specify, other than allowing you to dictate product length in 0.5mm increments).

So given that consideration, along with the fact that the corner will be totally hidden once constructed, I'm leaning towards just sticking with it rather than risk extra alignment headaches by slightly mismatched lengths.

But anyway, to answer your question the profiles themselves are pre-milled pieces from misumi. The cross pieces are HFSP8-5050 (50mm square profile, milled on 2 sides - so actually 49x50mm) while the larger ones are the bulkier high rigidity GFSP8-10050 (100mm x 50mm, milled on the 100mm sides, so true dimensions are 100x49mm). Misumi have a variety of milled profiles so you can probably find one that suits what you need - the issue is actually ordering it if you don't work for/own an appropriate company as they won't sell to normal plebs like us.