yes steel shops don't typically work weekends :wink:

1-1/2" x 1/8" wall is just the minimum I'd go - just looks nice IMO

anything less is like using a 2x2 piece of wood - sure it will hold.... but doesn't look like it would :wink:

Sorry Mindy I hadn't replied yet, I am on my first holiday in 9 yrs in South Africa for 14 days.

You can get away with 1" tube with a minimum of a 1/8" wall thickness. If you are putting any kind of covering on the stand it will help to support it from any movement. If you are concerned about it 1 1/2" x .100 wall tube is the best choice, keeps the stand light but still has more then enough support.

True enough, too bad you're there and I'm here. :lol:

It'll be covered, I don't care it will look like. :D I kind of like the "that won't work" look anyway. HA!

Awesome Greg!!! Have enough fun for me too! Oh, and take pics so you can share them with us! :p

The covering will be attached with magnets, so it will provide no support. I guess I should have mentioned that. :redface:

From everyone's input, I think I'll go with the 1" and get one size up from the 1/8" thickness (whatever that is). Maybe I will put some 45 degree braces in most of the corners too just for poops and giggles. Now I just need to rent a steel chop saw (whatever that's called).

If you have a mitre saw just get a 10" cut off blade.

True. I was thinking the clamp on the steel saws would come in handy while I'm trying to cut 45s. Is there not a lot of pull on the steel when doing 45s? I'll be able to hang onto it ok?

Not sure but I suspect it would be the same as cutting wood. Could always use a c clamp on the fence.

Smrt. I have no steel smrts.

Just think of steel like it's Ironwood. ;) Then your wood smrts will kick in. :)

Ha!

Of course it turns out "the next size up" isn't a common size. So I'm going with 1" with 1.125 thickness. I'll use some bracing. Hopefully it will be ok.