On Fri, 20 Jan 2012 11:49:23 -0800, SonomaProducts.com wrote:
Good detail. This is a really specific design. It includes metal work.

Thank you for the quick response and analysis. Your breakdown is a very
good estimate. The finished cross members would be probably from a 5/4"
and net out 1 1/16" x 1 1/16".

I'm concerned with the "x" cuts on the end of the pieces.

Here's a closup of the X cuts:
http://www2.picturepush.com/photo/a/...mg/7390145.gif

Here's another view of the x-cuts from overhead:
http://www3.picturepush.com/photo/a/...mg/7390146.gif

They need to be cut exact so they flush out with the metal. How would you
make the cuts on the end of the pieces. Would you use a small table saw.
Is that the best way or is it too dangerous to cut it standing up?

Also, someone suggested either anodized or powder coated aluminum. They
feel that spray paint would eventually wear off.

Which way do you guys suggest?

Thanks for the help!

I'm concerned with the "x" cuts on the end of the pieces.

Here's a closup of the X cuts:
*http://www2.picturepush.com/photo/a/...mg/7390145.gif

Here's another view of the x-cuts from overhead:
*http://www3.picturepush.com/photo/a/...mg/7390146.gif

They need to be cut exact so they flush out with the metal. How would you
make the cuts on the end of the pieces. Would you use a small table saw.
Is that the best way or is it too dangerous to cut it standing up?

The X cuts would be easy with a tenoning jig or some similar dedicated
hand built jig.