Aluminum Tube Thickness

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I want to build a rack to support the families skis off season.  It will probably support about 100 # and the weight will be dispersed well on it.  My plans are to make it fit over the recess above my garage door.  I am going to use square tubing.  There's alot of aluminum tubing for sale on eBay.  I was thinking about using 1" square tubing for this project.  The issue is with the wall thickness. A 1" x 48" x.050 piece of tubing is around $3.50.  I can get .065 and .125.  These are around $4 and $10 respectively.  My TIG welding skill aren't the best, but no ones life's gonna depend on these welds, and I plan on mounting it at at least 6 points to my ceiling in case a weld fails.  I'm thinking of going with the .065. So what would you go with?TA Arcmaster 300CM3XMT 304S22P12 suitcase feederX-Treme 12VSOptima pulserTA161SMaxstar 150STLHypertherm PM45OP setupStihl 020AVP, 039, 066 Magnum
Reply:If you don't have experience with thin tigging thin alum, go with the 1/8". .065 can be tricky with steel, and will be a nightmare in alum unless you have heat control down fairly well, especially if you are doing any welds at the cut ends of the tube. Don't be at all surprised if you blow holes in tube that thin or melt back the edges quite a bit. That or you will get very cold welds that won't hold much, because the filler is just sitting on top of the pieces. 1/8" is much more forgiving as far as heat control is concerned. At least think about using 1/8" for part of the unit. That would give you someplace to concentrate the heat a bit and then wash the puddle onto the thinner material.I'd suggest you get a few pieces to practice on prior to getting all the material you will need for the project. Alum tig is not easy. Even though this is a simple project from a fab stand point, the skill needed to pull this off with thin alum will make it a big challange for someone with very little tig skills..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:I would just contact your local aluminum supplier ( if you have 1). I think I pay about 25 dollars for a 24 foot stick it of 1" x .125".www.performancealuminumfabrication.com