Well here goes... Aluminium frame router design

[EddyCurrent]

Your frame is similar to mine, this is what I did;

http://www.mycncuk.com/threads/6565-...2425#post52425
But I also welded matching 10mm 'pads' onto the underside of the X box section, http://www.mycncuk.com/threads/6565-...4294#post54294
That was a mistake I think ! http://www.mycncuk.com/threads/6565-...4024#post54024
I always intended to use epoxy as well.

Instead of welding to the underside of the X box section, I would glue a piece of flat bar inside it using Gorilla Glue, similar to this ; http://www.mycncuk.com/threads/6565-...4981#post54981
because it increases the wall thickness of the box section allowing a secure fastening through the plates welded to the top of the legs.