Lightweight Aluminum Driveway Gate

Since we moved to our house, we've gone through two brand new vinyl fences (each set costing $700-800) due to cold Midwest winds and frequent use. I absolutely hated the idea of buying another vinyl fence, since they are so poorly constructed. Each fence used glue and screws directly into the thin brittle vinyl. Since the old hardware was actually decent, I decided to design and fabricate a lighter and stronger fence that could withstand high winds and be repairable in the future. Plus the aluminum frame should not corrode anytime soon!

If you do not own a welder, I suggest asking your local fab shop if they have any spare 2x2 aluminum tube and if they can weld it up for you. You can also modify gate width to suit your needs. In my case, I designed it for a 9 foot opening. You should be able to add an automatic gate opener, since the frame can handle the load.

7-14-23: Nearly one year in and it has held up better than any of the older gates. We've had some super strong winds and the gate took it like a champ while other gates in the area failed.

Material:
(2) DDSHNW3A, STAINLESS STEEL– 2" WRAP-AROUND GATE HINGE, https://www.hingeoutlet.com/products/black-stainless-steel-gate-hinge-2-wrap-around-self-closing-tension-adjustable-for-gate-gap-5-8-13-16-2-pack
(1) KLADV-P2-BK-KA, Keystone Black Nylon Polymer Key-Lockable Latch, https://www.amazon.com/gp/product/B07CJHYQSX/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&psc=1
(1) NW6143S-BK, Black Nylon Polymer Gate Handle and Gate Stop, https://www.amazon.com/Polymer-Handle-Fasteners-Included-NW6143S-BK/dp/B06ZYK29MF/ref=sr_1_23?keywords=Nationwide+Industries&qid=1661873677&sr=8-23
(1) NW38305KL-24SSB, Black 24 Inch Key-Lockable Stainless Steel Drop Rod, https://www.amazon.com/Black-Key-Lockable-Stainless-Steel-NW38305KL-24SSB/dp/B06ZY8F2HT/ref=sr_1_26?keywords=Nationwide+Industries&qid=1661873677&sr=8-26
(2) 5' high vinyl panel of your choice (cut to length during assembly)
(2) 68" long 2" aluminum angle (welded)
(4) 53" long 2x2", 1/8" wall aluminum tube w/ 45 degree cuts (welded)
(4) 48" long 2x2", 1/8" wall aluminum tube w/ 45 degree cuts (welded)

(1) 1kg of white PETG filament

Fasteners:
Screws for Latch, gate handle, and drop rod
(1) 93395A263, 316 Stainless Steel Hex Drive Flat Head Screw, 90 Degree Countersink, M4 x 0.70mm Thread, 20mm Long, Packs of 50, https://www.mcmaster.com/93395A263/

Screws for printed brackets
(2) 90909A419, 316 Stainless Steel Flanged Button Head Screw, M6 x 1 mm Thread, 14 mm Long, Packs of 50, https://www.mcmaster.com/90909A419/

Tools:
(1) 3.3 mm drill for M4x.07 threads, https://www.mcmaster.com/5058N58/
(1) 5/16 drill for M6x1 Threads and latch spindles
(1) Metric Tap Set (got mine for less than $20 at Harbor Freight)
(1) Welder (if DIY)
(1) Saw or similar for gate panels & aluminum tube
(1) Drill press w/ clamps (hand drill could suffice)

(1) 3D printer (or hire one)

Bracket Print Settings:

Infill: 25%, Gyroid

Perimeters: 3

Supports: ON, only from build plate

Brim: OFF

Resolution: .20 Quality

MTL: PETG