Brad, I can't remember, do you have a table saw? or access to one?
I like the idea of metal, doesn't have to be aluminum if your going to paint it, and there are lots of paints out there that you can get any look you want really.
but if you are set on a wood look you could go with 1" AL or steel tube and then dado a 1" channel in your wood to conceal it in the wood. now I would do this for you, but you never come to visit
Steve
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