How to make this truss structure?
I would like to make the truss structure shown in this image. What would be the simplest method to join the truss members, without substantially adding to the weight? I am not a wood worker, i.e. would not be able to make tight-tolerance joints. I can can clamp wood together, I can use a miter saw, and I can drill :).
I went for trusses, b.c. I wanted a light, stiff and (relatively) easy-to-make structure. I simulated this in Inventor for oak and wallnut; both gave acceptable deflection and mass (a structure made of 6061 Al tube extrusions came up heavier). I do not know much about FEA of assemblies, so I simulated as if the whole thing was a solid wood structure, with the long grain along every truss member. The members are 12x25mm rectangles in cross-section (1/2 x 1") and the central bar is 12x50mm (1/2 x 2"). The simulated 500N force was applied to an area in the center (12x100mm, 1/2 x 4") and the two constraint "pins" are 1230 mm (~4") apart. How to joint this together while "living up" to the simulation?
I read on this sub that wood glue works best, as long as it's long grain to long grain (if I understood correctly). Can I use wood gussets (e.g. oak plates 1/4 x 2 x 2" == 6 x 50 x 50 mm) at all corners? Should these gussets be plywood or solid wood and, if the latter, how do I orient the long grains? I also considered aluminum plates (simulated 3 x 75 x 75 mm == 1/8 x 3" x 3"), but these would add a lot of weight (50% of the mass of the simulated wood structure), and I am afraid that the bolted connection through wood won't be as strong as glued wood.
I also considered 3D printing a lug for every joint in nylon plastic.
