So, Spring/Summer, 2024, I'll be replacing my rotten cedar deck rails.

[OAITW r.2.0]

Due to my separation, I was out of home for 10 years. Lack of painting the cedar posts accelerated their demise. So, new design is planned. I'll be using approx 1-7/8 - 2" dia Aluminum tubes, bronze anodized seated in pre bored holes in painted pine 2" x 4"'s..

My question is, what is a reasonable wall thickness to maximize crumple resistance vs. cost. I'm thinking a 1/8" wall will be sufficient. Any thoughts? I'll be buying a few extra tubes, as the design will allow easy replacement.

[cyclonefence]

1. I'm sorry I can't answer your question

although 1/8" seems flimsy to reinforce (veneer?) the posts. I'm probably not even understanding your problem.

But I wanted to ask you--cedar rots?! I thought it just weathered a nice gray but never rotted.

[OAITW r.2.0]

2. I am buying aluminum tubes for my posts.

The OD will be @ 2" diameter. What I need to figure out is min wall thickness that will given me maximum protection against crumpling. 1/8" wall in a 2" outside dia tube seems like a strong tube to me. As wall thickness increases, costs go up a lot.

[cyclonefence]

3. Oh thanks

that makes a lot more sense to me

Good luck with your project--it sounds like it will be rewarding, and maybe a little fun to do

[OAITW r.2.0]

4. It will be fun.

The deck (wraparound) is currently about 1000 sf. I will be painting the deck (pressure treated), first time in 20 years....but in great shape. I re-stained the house and garage in 22/23 . Adding 800 sf of deck space and then will be rebuilding the railing system. Primarily 4 and 8 foot box sections for the railings. Green trim for the railing boxes to match the window/door trim. Should be fun!