Quote Originally Posted by CraftyGeek View Post

Right now, after having a quick look into material costs a bit more closely, I don't think I can go for a new full ally profile build as I simply don't have the funds. From a quick glance - ally box & steel box don't actually seem to work out that much cheaper.
Box section steel is half the price of Ali box section, I pay around £20 for 7.5mtr 50x50x3


Quote Originally Posted by CraftyGeek View Post
As welding isn't an option - how would you suggest creating an accurate solid frame out of box stock?
I have a metal supplier near me that could in theory cut pieces to length for me - but how best to join them?
Using plates Drilled and bolted to the frame.! . . . Thats why a decent pillow drill is so usefull, almost essential if you want an easy life.