I'm using a 6" piece of 1 3/4 x 3/8 wall round alum tubing in a gusset assembly.
Turns out instead of the full 6" piece, I could do quite well with three 1" pieces, spaced uniformly along the 6" span.
Clearly this saves material (and fairly hefty material, at that), but what about the increased mfg pita??
How are scenarios like this evaluated? Yeah, lotsa spreadsheet work and "what ifs", but it seems the decision almost always favors minimum material (and the cheapest material poss.), and I guess this really depends on quantities, tooling, machines, etc.
In my case, I think I'm going to go with the full 6" piece, just to save a bunch of futzing around with separate 1" pcs.
I guess this is what bean counters are for??