Joining aluminium extrusion lengthways

[JAZZCNC]

Think Your going to have to drill some holes and use standard connector elements or T-nuts. Will be tricky on that angle piece thou.!

[EddyCurrent]

Thanks for replies so far, it confirms what I thought even though it seems a basic and reasonable requirement.
I think I'll be drilling like you say and making a hardwood spline + Gorilla Glue for the angled piece.

[D-man]

Possibly a stupid idea but how about a strip of Ali or strong plastic the shape of a double ended T nut then knock it in and cover with profile cap end

[mekanik]

Hi Eddy
You will have to drill the 40x160 right through and use stud iron same dia as the slot width, small lengths of flat bar drilled and tapped to fit the 45deg section and you want a hole in the 40x80 section for the stud iron and also a larger hole for the nut you are going to have to make to tighten it all up, you need some hex bar to make the nuts, just turn the hex down to to a slight clearance on the larger hole and drill and tap to suit your stud iron, or just machine a sleeve and fit some nice shiney dome nuts, ormake the hole big enough to get a socket in to tighten and fill the hole with a plastic plug.
The 40x160 could be drilled from either side as you have the accuracy of your CNC machine.
Regards
Mike

[EddyCurrent]

I've ordered the parts now, will update with pictures once finished.