Ok, anything for a laugh.
Thinking about the construction of my router base at the moment. I am going for a welded base of either aluminium of steel. I can weld steela bit but not ali and I can get either of them welded in the department however ali will take more setting up and the technician time is scarce enough without doing things for me so leaning to steel.
Anyway here are a few ideas. I got some inspiration from a book called "Design of Weldments" by Omer Blodgett. The book is really good and describes how machine bases and other structures of superior stiffness and rigidity than cast iron can be made by welding steel providing the correct structure is formed.
The basic way to get a really rigid box is to add gussets that run diagonally in a criss-cross nature. It seems that having these members at 45 degrees to the "box" is important and there is a great picture in the book of test structures showing this.
There is also mention of adding slots for fixing things to beds. This reduces the strength of the bed unless the individual sections of the bed are tied together some how.
Attached are a few possible methods of doing this, the u-channel one is much like the book, not as good as the gusset lattice but good. I am going for the one with the V channel (my own design), I think I can make this lighter than the other and just as stiff if not stiffer. I was going to make a stiff box and add aluminium t-slot material to the top but with this method I will end up with steel slots and also save some cash which I really need to do. The choice of V slot is based on availability, it makes the machining a tad tricky but not really that bad. I am not sure but I think the V may also be a bit stiffer.
Sorry to waffle, just thought I would start the ball rolling on this subject.