Picture of 8020 Fastener Alternatives
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

Picture of 1/4 20 - socket cap bolt and diy plate
diy 8020 plate on gusset.JPG
diy 8020 plate in place.JPG
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.

Step 2: Socket cap and square nut - 5/16

Picture of Socket cap and square nut - 5/16
socket cap in place.JPG
The square nut fits quite nicely in the slot.  You must use a washer since 3/4 will push into the back of the 8020 rail.  (I assume a 5/8 length bolt will work fit perfectly, yet did not try it.)

Here are the parts.  I purchased mine from Lowes but I've added links to online sites.

5/16 Socket cap @ 3/4
5/16 Lock washer
5/16 Square Nut

Step 3: Carriage bolt 5/16

Picture of Carriage bolt 5/16
carraige bolt in place.JPG
A 5/16 carriage bolt works great too!