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Old 09-14-2015, 10:50 PM
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Another option if you're rebuilding is to use stainless 304 tube. Switching to 304 from aluminum with the same dimensions will give you close to 3x the stiffness and and can be brushed to look just like aluminium. It's also available in solid rod for greater strength, although you don't gain that much. 1/2" Ornamental stainless tube looks to be around $3.50 a foot, solid rod is a bit more at closer to $5 a foot. That's metal supermarket prices which I believe will ship to Stoon, but you might find a local source cheaper.

Also I see you mentioned longer radius bends, keep in mind encase you didn't know, bigger radius means more flexibility, so shorter bends offer greater stiffness.
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