Milling Slots in Tube to Reduce Weight?

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Greetings, I am contemplating making a frame out of steel but I would like to reduce the weight of the steel frame as much as possible without compromising strength. The idea that I had would be to take the square steel tube and route 2 inch slots separated by 1 inch of solid metal into the tube. So the tube would have 1 inch of solid metal than a rounded slot two inches long and then another inch of solid metal. The slot would be roughly half the width of the tube. So even on the inside the corner of the tube will still be there. Would this be a workable solution to reduce weight without compromising strength. What constraints should I observe (should I only do two sides and leave two solid? Would it be better if I do all of the mitre welds first before cutting the slots? Would I achieve a similar effect if instead of slots I simply drilled holes in the frame with about the width of the hole between holes?I would also like to know if this would work for aluminum as well. Thanks to the welding professionals answering my silly questions.
Reply:Need more info. Size of frame configuration of frame intended weight you plan to suport...Timmetalcraft by mooseSoutheast Michiganhttps://www.facebook.com/Metalcraftbymoose  Stupid Hurts!!
Reply:There is a lot more to weight savings than simply picking material at random and chopping holes in it to remove material. If you want something as light as possible, you need to look at the whole picture.In general the larger you make a tube, the thinner the material can get and yet retain the same resistance to buckling. You can quite often use either the same weight in material or less weight, yet get a much stronger structure simply by going up in size, yet going thinner in wall thickness. Also the design of the shape plays a large part in this also. You can hold up insane amounts of weight with a corrugated sheet turned on edge. Even more so if you take that sheet and wrap it in a circle. That is because of the way the sheet supports itself with all the folds. A sheet metal cabinet will hold up quite a bit of weight and remain stable and light weight. You can reduce the weight even farther with properly located holes, but put those holes in the wrong place and it all comes down.We really need more info if you want good suggestions..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:Why don't you make the Fame out of Angle, the same size as the tube and then you have lost about half the weight, Can you use aluminium?
Reply:Electrical strut has the holes already cut, can you use that for the frame and then you have it already holes cut and some finish already on it. I've seen it in painted and galvanized. Would that do what you wanted.