I originally built an MFT knockoff with 8020 about 10 years ago. (Man, has it been that long?) It was cheaper for me because I had access to the material. I still have a workbench I made from the stuff and need to find a way to use it more as it is a good bench. Right now it is a tool collector. I have a problem with horizontal surfaces as I cannot keep myself from piling things on them, but that is just me.
The bores used in the 8020 system to connect extrusions at a right angle can be machined with a router and a template. I have done this and they come out beautiful, but one needs to really understand the force vectors developed and not get too greedy. I believe they are 13/16 diameter but don't take my word for it. Measure one made by the factory before you try machining any yourself. I do also believe you could do them on a drill press with a carbide tipped Forstner bit. I think one can get such an animal from Rockler with a 3/8 shank. They are too long as is and would need to have the shank cut shorter so the tool would be much more rigid before use. You would essentially be turning it into an end cutting end-mill. Either way, patience is a virtue but there is nothing that compares to fabricating the components for yourself in exactly the lengths you need. Even when I did mine with arouter it was more for the kick involved as I have access to plenty of equipment to do it easily, such as a Bridgeport mill.
The bores used in the 8020 system to connect extrusions at a right angle can be machined with a router and a template. I have done this and they come out beautiful, but one needs to really understand the force vectors developed and not get too greedy. I believe they are 13/16 diameter but don't take my word for it. Measure one made by the factory before you try machining any yourself. I do also believe you could do them on a drill press with a carbide tipped Forstner bit. I think one can get such an animal from Rockler with a 3/8 shank. They are too long as is and would need to have the shank cut shorter so the tool would be much more rigid before use. You would essentially be turning it into an end cutting end-mill. Either way, patience is a virtue but there is nothing that compares to fabricating the components for yourself in exactly the lengths you need. Even when I did mine with arouter it was more for the kick involved as I have access to plenty of equipment to do it easily, such as a Bridgeport mill.
