How to stiffen 1/2" aluminum tube?

[Reef Pilot]

Originally Posted by Myka

I was a bit concerned about that, but I thought it took dampness to cause an issue. What if I wrap the steel in something first, like Tuck Tape or vapor barrier plastic?
Otherwise, option #1 sounds nice.

That's true, but humidity is enough to start corrosion. With aircraft we use zinc chromate epoxy for all joints which seals against moisture, and is also a glue for extra strength. But you can't buy that stuff in a regular hardware store.

Not sure how heavy the fixture is, but bear in mind this only strengthens the bent tube area, and if your tube size isn't large enough, you could still get bending and flex with the weight.

If you need more strength overall, you can make the cut tubes (or gusset) longer. A larger gusset can also be rounded on the outboard side towards the middle to provide more clearance if necessary (and it will look prettier). For the gussets, I would use .040" or .060 sheet pieces. Your local metal shop usually have scrap bins, and should let you pick out small pieces at no cost. Oh, and use T6 6061 aluminum for superior corrosion resistance.