Looked into it a bit more and looks like the material they use is about 3mm thick (1/8th in the USA). So I could have reduced the weight by about 40% (or about 20kg) by using 3mm and a wrapped form on the sill as Strangy suggested.
Sill profile is not quite 90 degrees but will definately go the formed route on V2 as Tombie suggested. See attached
Got the material already and half way through the build so will just finish these off as a very heavy "prototype" to sort out the bugs for V2 sometime in the future.
So for the moment V1 will remain 20kg overweight and tough as a brick **** house - like some of the ladies I know
Will post pics and CAD file for 3mm version for those wanting to try their own build - but for my money unless you want a project - just buy them from Gordon it's easier..
Last edited by dullbird; 26th August 2014 at 08:19 PM. Reason: can't spell
You make any head way in the CAD? I'm just embarking on building some sliders in Autodesk Alias. Are you willing to share the file?
Any tips would be appreciated.
James
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