Originally Posted by
tpolley
here ya go. i built these cross members at work last week.
they're 1 inch by 1 inch by 1 inch by 1 inch by 1 inch. it took some fancy fabrication. they're so small, the piece wouldn't fit in the brake once i made it to the 3rd and 4rth brake. i had to do some of it with a rubber mallet and by hand. i did it before work so i didn't have time to take pictures.
i finally got around to riveting them to the frame/deck. it really added a lot of support to the deck. i can stand on it now and it doesn't act like it's going to cave in.

Looks good! You could also buy some 1"x1" aluminum square tubing, or even 1"x1" aluminum angle and get similar results. One of our shops has a power brake that will get down to 3/4", unfortunately it isn't ours.
Aaron