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Your definitely going to overpay for your SS tubing from Grainger not to mention the amount of waste that will probably come out of having to deal with 72" lengths. Going through an actual steel supplier and buying 20' lengths you could probably get 1.5x1.5 with an 11ga. wall (1/8") for a $1...

Just finished my build this week haven't even had a chance to brew on it.

The cleaning aspect shouldn't be overlooked, spilling wort on to a hot frame cause some pretty good stains, years of scrubbing on such a soft material, not sure how some cleaning agents will react with the AL. Just even the way AL oxidizes is enough to make me stay away. AL looks really nice...

Good point.

250 lbs is overkill IMO. 100 lbs should be fine. My stand is probably 250 with keggles. Add another 100 lbs for grain and water.

250lb casters!? Way overkill IMO. 100 lb capacity and you'd be fine. My stand is probably 250 with kegs, add another 100 lbs for water and grain, and I think I'm going on the high side of weight

I like your idea of hidden pieces to keep your kegs on to keep it clean looking. I rolled up some 2" strips of 12ga and set on the outside. The route I took is very visible but I also think still has that clean appearance. Just something else to think about should the hidden pieces not work, and...

I'm just finishing up a Brutus type build. I was able to make it from 2-24' lengths of 1.5" 11ga. sq.tube. The top of mine is 66X17" I wanted to really oversize it 1, I'm not to concerned about the space and 2, should I want to ever upgrade kettles I'm not starting from scratch with my stand as...