While building my cnc mill, domo, I found myself annoyed at the crazy go nuts shipping cost of 8020s fasteners.  Seven dollars is a bit absurd for a part that weights virtually nothing.  Being miserly and impatient I found a few other simple ways to join gussets to 8020 rails.

Step 1: 1/4 20 - socket cap bolt and diy plate

There's not much to say about this little diy plate except that you can make it in minutes.


Hot Rolled 1/2 steel - You can can get this at any bigbox or order it here (.59c for 12")
Socket cap bolts - the ones shown here are from 8020 as they were left over, however you can use any 1/4-20 socket cap screws with a washer if required.  These are 1/2", yet 5/8" lengths should work.

You only need to drill and tap two holes on 1.5" on center or what ever distance fits your application.
Thanks for sharing this. It really helps. I've been thinking I should probably get some <a href="http://www.componentforce.com/category/14/square-caps" rel="nofollow">square caps</a> for the projects I'm working on. How long did it take you to do this?
I really need to pick up some <a href="http://www.componentforce.com/category/14/square-caps" rel="nofollow">square caps</a>. I have been thinking about getting some for a while, but now I think that they will be perfect for my project. Thank you so much for this great instructable.

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