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Re: Is there a method to use regular 1" square aluminium extrusions?

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Imagine a square sleeve. Split it diagonally. Incorporate 608 bearing mount points so you can have bearings riding on all four sides. I would do a 2-1-2-1 pattern for the bearings. You can zip tie the halves onto the square tube or spring load them or screw them together.

This is assuming that you have a 3D printer already or have access to one.

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