I'd recommend two great businesses that also support the 'buzz as partners; DRE in Denver and Riverboatworks in Salida. I've had really good aluminum frames from both of them and they both do custom aluminum work. Their prices are similar and really haven't gone up much as aluminum has so I'd expect a really fair deal from either.
AAA in Denver will do most things as well (although I share concern on 3/4" aluminum frame). I spoke to AAA and DRE before I bought last year and found AAA a bit more flexible than DRE on what they would do that was "atypical". Don't get me wrong though, I think DRE makes a nice frame and they are good guys there (bought lots of other stuff from them). I'd suggest talking to them both. Riverboat is very flexible as well, just not convenient if you live in front range.
I like DRE for many things. However, when I was in the market for a welded aluminum frame, I knew what I wanted and went to DRE and got a lot of push-back on features that I wanted. They told me that if they welded some of the joints that they wanted to use fittings on, the frame would bend and sag there. I also had trouble with welds on a large dry box that I ordered from them cracking repeatedly. They were always nice about fixing it, but it leads me to wonder how good the welding is there.
In the end I ponied up and drove to Flagstaff to get a frame from PRO, who builds exactly what I wanted, with no pushback. I think it was also cheaper than what DRE quoted me.
This front bay is one continuous piece of 1 5/8" od 6061 aluminum tube, supposedly 6061 is not bendable, but i looks like it bent just fine to me. Probably could save you some bucks if you'd like to pitch in with some labor. I can bend, weld, notch any thing you design. Im in ft collins, not a professional just a boater.
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