80/20 aluminum T-channel extrusions

This page includes my notes on 80/20 aluminum T-channel extrusions (as part of my CNC machine project). This is the first project I've used this for, and it's very handy stuff. Not cheap, but very solid.

(UNDER CONSTRUCTION)

Understanding the Product Line

80/20 has an extensive product line. You can narrow things down quickly by just looking at the popular "15" product line, which includes extrusions sized in 1.5" increments (e.g. 1.5", 3", 4.5", etc.)

The naming convention "1530" means 1.5" by 3" (e.g. slightly smaller than a wood 2x4). Other common sizes are 1515, 1545, and 3030.

The 15 series comes in three "styles":

• Standard
• Lite, thinner/lighter than "standard"
• Lite/Smooth, thinner/lighter than standard, and without grooves on the outside.

Where to Buy

80/20 does not sell direct, they only sell through distributors. Use their Web site to find a distributor near you. Unfortunately, many of these distributors have varying degrees of sophistication when selling on-line.

You CAN buy "direct" from 80/20 through Amazon. You can buy stock lengths of various profiles: 24", 48", 72", etc.

There are also competitors offering "compatible" extrusions, at slightly cheaper prices. I've had very good luck with the extrusions from Automation4Less.com. They also have a handy Web form for cut-to-length orders.

Cutting

The key to cutting is getting smooth and square ends. Many projects depend on this for the resulting assembly to be square. Hand cutting, or Sawzall cutting is probably not going to work well.

I've had excellent results cutting CAREFULLY on a table saw, with a carbide blade. Feed very slowly, and wear good eye protection. I don't use my best wood cutting blade; I use a mid-grade quality blade. Make sure your blade is square to the table before you cut.

I chop saw should also work well (with a carbide blade); I haven't tried it.