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Message: <blockquote data-quote="Driftless" data-source="post: 504800" data-attributes="member: 34665">I'd do some research on who around you would be using the lengths of aluminum you want.  The manufacturers of aluminum would know who uses it as the ship it to them.  The distributors also.  Widen your search until you find it as there's not too many aluminum manufacturers.  For input to what you asked, my two cents.You could put hat channels on both sides of the weld, then connect the tops of them to each other with a thicker piece of alum, welded to the channels.  On the outside, weld an alum 'strap' bridging the joint, wider than the width of the hat channels.As with any structural framing, avoid joints all in one spot from different planes. Stagger them.</blockquote>