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.

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

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

A 5/16 carriage bolt works great too!
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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