Thanks Dave,
More good info as usual!
I would like to get some accurate measurements on the profile of the bed side like pictured, or I can guess at it.. But draw it in Auto-CAD, then present it to a well know aluminum bed manufacturer or two. With luck someone will be interested enough in the shape/style to offer it as a regular production item and then they can foot the bill for the aluminum extrusion dies to make it possible.
It may be wishful thinking, but worth a try, as many of these aluminum bed manufacturers already have custom dies and extrusions made, so they already have contacts and suppliers in that field.
There is also a chance the side rail shape can be made in multiple operations on a press brake, in steel or aluminum. Then the corners could be turned on the lathe to the same outside profile, and bored on the inside to give the nominal rail width. Cut the circle into 1/4's on the band saw and you have the 4 corners. The sills and cross rails/joist are stock aluminum channel or I beam. Major cost on this option is the corners, mostly in material cost for the aluminum chunk, unless heavy wall tube could be found, about 12-14" OD with 2" wall thickness?
Grigg
