So, here is my noob question: What are the best ways and methods to join aluminum when doing a build? I understand that it is possible to use pop rivets for thinner aluminum (like alu angle and plating), screws (for solid pieces), and adhesives (such as JB weld). How do these compare and what are the better methods? I see alot of alu angle being used, but doesn't that leave spaces between the frame and the side plating? I used Sketchup to show a couple examples of some possible joints that come to mind. I was thinking of using solid 1/2" bar for an upcoming project, but I'm not sure how best to do the joints.
It really depends on what equipment you have available and how you build. There are also plastic corner joints that fit inside square tubing, and sheet metal can be combined to make the joint too. Some clever person here made corner brackets out of bent sheet. ... I'm totally not answering your question here, am I? I'll come back when my head is clear.
Strongest - Weld Next - drilled/tapped with screws Then comes pop rivets - easy to do, can look nice, but uses weaker materials as you mentioned (i.e. sheet and angles vs. solid) As Cheaps mentioned if you use square tube you can get some nice plexi connectors or alu connectors to put it all together I wouldn't even consider JB weld on anything structural, it can get really brittle
@Nanosec: Good to know about the JB Weld, maybe I would just use it to hold the pieces in place during construction, but still plan on using screws, connectors, etc. For the hollow tube connector option, I searched for a while and found this website showing some connectors: http://www.eztube.com/connectors/connectors.html I assume that this is an example of what you both are referring to. Do you think they will last, or would you still put a screw into the side to make sure it doesn't slide out?
I think it would be enough to use only the connectors. From my experience you have to really hammer it into the square tube, so getting it out would probably need as much force, if not more.
Can you buy those at a normal hardware store like Home Depot, or is it best to source them online? Also, if I was to use solid bar (let's say 1/2"), how do you screw a 3-piece corner together?
At least in Sweden you can buy similar joins as the ones you linked to at Hornbach or Bauhaus, who stocks mostly everything for building or furnishing (or demolishing if you want to do that ). So if Home Depot is anything like that they should have something similar at least. If you want to join three solid bars one have to be offcenter in some way, look at this post for an example.
Another option for welding Aluminium with out a Tig welder is the Durafix Aluminium Weldnig rods. All you need is a blowtorch and a bit of patience. Im intending to try ti out on my scratch build when it comes time to start. Have a look at the link: http://www.durafix.com Its available world wide (to the best of knowledge)
