[brushlessboy16]

Originally Posted by JThiessen

You need to figure out how to square it up too. If by chance you get a piece of AL Ang extrusion that is actually 90degrees, box it up, and bury it in the yard, cause its worth its weight in gold! Most of the time, the angle is less than 90, so you can shim under one edge to get it sit square. Best method is to find a piece that has been machined square.

hahaha will do , shimming shouldnt be that hard- why not just bend the aluminum into the correct angle?. im wondering just how much flex there will be in the chassis with that composite center brace?

Originally Posted by JThiessen

Why would you want to fuse the corners? Just bend it in a U shape. If you make it an inch or so longer than you need, you can also make a cut along the corner, then bend the remaining tab inwards.

Yes, there is a product that fuses lexan quite well (type 3 acrylic adhesive). Unfortunately, its fumes have been proven to be quite harmful to us humans and is therefore tough to get ahold of.

Like Linc said - Kydex will likely be easier for you to work with, and is plenty strong.

Alright, i would think that you would need bracing in the corners- -but then again you know better then i :D