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I am thinking about doing the same thing. This guys plans look really sweet and also bullet proof. Check it out. Its the way I am going to do it. Well if I can convince the teacher!
I do wonder why I posted it here. Sorry about that. Anyway, here's some rails I found that I like... http://custom4x4fabrication.com/armor.html
What do you think about the 2x4 square tubing ones?
I think square vs round can be something of a preference thing. A lot say round tubing is stronger, a lot of others say square tubing is stronger. I'm not sure which way is right tho...
yeha i would have to agree with this guy but i think that side wall thickness has a lot to do with it as well, i just had the local high school metal shop build mine and they are made out if 2x2 3/16 sidewall so i think that they well be just fine. picks up soon i hope!
square vs. round strength depends on application. square is stronger in bending if the force impacts the flat side of the square.
my 2x2 .120wall rails are still holding up great. they have lots of scrapes but no significant dents. I have like 5 or 6 supports going to them also, so they haven't bent along the length. If you only have 2 (or 3?) supports you should step up the wall-thickness.