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Originally Posted by eddugo
... a new one in place of the broken by screwing it in on an angle next to the old one ...]
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Quote:
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Originally Posted by BrucePerens
... fabricate a new bar with holes in places that haven't been damaged ...
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I'm a little nervous about this idea of drilling new holes near the old ones, or enlarging the existing hole by inserting the screw at an angle. Remember, the screws are going into 1" square aluminum tube - not steel - and aluminum isn't especially strong. Adding new or larger holes in addition to the old ones might weaken the tube enough to cause it to deform. I may be wrong, but a more conservative approach would be to stick with the existing holes if you can.
I have replaced a length of this aluminum tube, and though it is not impossible, it wasn't much fun. It was a long time ago, but I think I could find the thread if it would help.
Bill