Attatching Sheet to Tube

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I don't know where to post this, so this forum looked about right.In a previous discussion, I had asked questions about building new sides for my mason dump.I ordered some 1 3/4 steel square tube yesterday to build the frames.I am going to attach aluminum diamond plate to them.   Questions is, what is the best way to attach the aluminum to the tube, securely that'll take a little beating.  At one point in a past project I tried self tappers, they sheared off.  I ended up drilling all the way through the sheet and tube, and bolting.  Boy was that a PITA.  I'd like to not have to do that, but I'd like the rigidity of it.Someone mentioned a layer of tape, maybe that'd cut down on the fasteners.
Reply:What are you putting in it? From your previous post, I thought you were a scaper from the looks of the body and it was for leaves or wood chips.Did you shear the screws or strip them out? Sheared says to me there was a force across the sheet and you need a larger dia. to keep it from failing. Stripping out says that there is weight pushing out from behind. Thru bolts would make sense for that.If it's weight on the inside pushing out, the first thought is put the alum on the inside of the frame. Yeah it won't look as nice but then all the fasteners have to do is hold it up. You could put a strip across outside face where the steel frame is and use it like a giant washer to support the alum. You'd need less thru bolts that way.I'm not sure why thru drilling was a PITA. I'd drill the frame first, preferably before it was assembled. You can drill on the ground or in a drill press where it's simple to do. Then use clamps or  a few self tapers to hold the alum in place and drill thru the predrilled holes in the tube to get the holes in the alum to match up easy. You could even run long self tappers thru from the inside temporarily to hold it if you have someone to hold the sheet in place. Just pull them out one at a time as you do the thru holes and replace them with bolts as you go. I'd get a longer bit to do this than the standard length bits. Depot sells long bits (I'm thinking 12") and you can order various length bits from places like MSC or Graingers.If the pain is getting the bolts thru the holes, oversize the hole. Also if you use longer bolts, they are easier sometimes to push thru. Then cut off  the extra after you nut them down..No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:Steel tread plate would be less expensive and alot simpler to attatch and no worries about it comming off, just weld it in place.   You can use thinner steel than aluminum and have the same strength with a bit more weight.MM350P/Python/Q300MM175/Q300DialarcHFHTP MIG200PowCon300SMHypertherm380ThermalArc185Purox oaF350CrewCab4x4LoadNGo utilitybedBobcat250XMT304/Optima/SpoolmaticSuitcase12RC/Q300Suitcase8RC/Q400Passport/Q300Smith op
Reply:I've used butyl tape with good results when joining aluminum http://www.plustape.com/BK/index.htm . It's especially good when you're trying to prevent  a reaction between two dissimilar metals such as a steel frame to aluminum skin. It adds a lot of strength as well....Mike
Reply:DSW, arborist...woodchips.It was a PITA in the past drilling because I had the self tappers every 6", so I replaced them all.  Over 200 a side I think, hahaha.  It was force pushing from the inside out, heads ripped right off.I canceled the steel order.  Thinking after painting, attaching, and whatever else, I might as well build it out of aluminum from the beginning.  I am a sucker for aluminum, and fixated on keeping the rig as light as possible.  I guess I really need to figure out what I want to do.
Reply:Ok my 1st guess was right. When you said mason's body I thought you planned to fill it with sand or busted crete. I could see you getting 10 to 15 ton of sand in that size body on a 1 ton frame..No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:What size steel tread plate would be equivalent to the strength of 1/8" aluminum tread plate?  I can probably go with a 16 gauge tube right?
Reply:The floor of my utility body was made with 16ga steel tread plate.  16ga is pretty strong if supported every 1 to 2  feet.16ga = .063" or about 1/16"14ga = .090" or about 3/32"12ga = about 1/8"MM350P/Python/Q300MM175/Q300DialarcHFHTP MIG200PowCon300SMHypertherm380ThermalArc185Purox oaF350CrewCab4x4LoadNGo utilitybedBobcat250XMT304/Optima/SpoolmaticSuitcase12RC/Q300Suitcase8RC/Q400Passport/Q300Smith op