DIY Golf Simulator Frame: 1.0mm vs 1.6mm Aluminium Tubing
Quick answer: Both 1.0mm and 1.6mm aluminium tubing can build a working DIY golf simulator frame. 1.0mm wall tubing is cheaper and available at most hardware stores; 1.6mm wall tubing is noticeably stronger and more stable, resists denting from direct hits, and adds only about 644g to a standard home frame. For a long term, professional quality enclosure, Aussie Golf Sims recommends 1.6mm, and includes it in the RooBox Framing Kit at a price similar to 1.0mm locally.
When building a DIY golf simulator frame, the strength of the frame plays a major role in how stable, safe and long-lasting your setup will be. One key factor that is easy to overlook is the wall thickness of the aluminium tubing used to build it.
In Australia, most local hardware stores stock 25.4mm outside diameter (OD), or 1 inch, aluminium tubing with a 1.0mm wall thickness, while specialist suppliers offer a wider range. At Aussie Golf Sims (AGS), we stock 1.6mm wall aluminium tubing, marginally thicker than most hardware stores. But what does that extra 0.6mm really mean for your simulator, and is 1.0mm tubing suitable for your frame? Here is the honest comparison.
In this guide: Quick comparison · Strength · Long-term durability · Weight · Cost · Availability · Which to choose · Alternatives · FAQ
1.0mm vs 1.6mm Aluminium Tubing: Quick Comparison
| Factor | 1.0mm Wall | 1.6mm Wall (AGS RooBox) |
|---|---|---|
| Strength | Flexes under high tension; can dent on direct hits | More stable; far less likely to bend or dent |
| Long-term durability | Fine with padding and careful use | Keeps the frame square for longer |
| Weight | Lightest | Only ~644g heavier on a standard frame |
| Cost | Cheapest, hardware store priced | Similar price via the RooBox Framing Kit |
| Availability | Every major hardware store | Specialist suppliers / included in AGS kits |
| Best for | Budget and pure DIY builds | Long-term, professional-quality enclosures |
Strength and Rigidity
- 1.0mm wall thickness: more likely to flex under high tension and heavy loads. Direct golf ball hits may result in irreversible dents and/or bending.
- 1.6mm wall thickness: holds the enclosure and impact screen in a more stable position during use. Far less likely to bend or dent under direct impact, though strong shots (like drives) can still cause minor denting.
Long-Term Durability
- 1.0mm wall thickness: suitable initially, but may dent or bend with long-term use, especially from direct golf ball impacts. With added padding and careful use, it can still work well for DIY setups.
- 1.6mm wall thickness: much less prone to warping under tension and better at keeping the frame square for longer. Structural damage is unlikely, and overall long-term durability is significantly improved.
Weight: Is 1.6mm Too Heavy?
1.6mm wall tubing is approximately 36% heavier than 1.0mm wall tubing per length. But in a real frame the difference is tiny: a standard 3.0m (wide) x 2.6m (high) x 1.5m (deep) home simulator frame built from 25.4mm OD x 1.6mm tubing is only 644g heavier than one built using 1.0mm. In other words, almost no real difference in weight, but a huge difference in strength.
Cost Considerations
- 1.0mm wall thickness: generally cheaper and widely available from hardware stores, great for tight budgets or DIY focused builds.
- 1.6mm wall thickness: slightly higher raw cost, but the longer lifespan often makes it more economical overall. AGS provides 1.6mm aluminium tubing in The RooBox Framing Kit at a similar price to what you would expect to pay for 1.0mm locally, making a sturdier simulator more accessible.
Availability
- 1.0mm wall thickness: readily available at all major hardware stores, and the most common choice for DIY projects.
- 1.6mm wall thickness: harder to source through standard retail channels and often only found via specialist suppliers. AGS includes it directly in our framing kits for consistency, convenience and better build quality.
Which Aluminium Thickness Should You Choose?
The right choice depends on your priorities:
- If you are building a DIY setup using mostly hardware-store materials, 1.0mm poles can be sufficient, especially when paired with extra padding.
- If you want a long-term, stable, professional-quality enclosure, AGS recommends 1.6mm wall thickness for the added strength and peace of mind.
Alternative: Galvanised Steel Tubing
If you prefer DIY, cannot source 1.6mm aluminium, or are concerned about durability, most hardware stores also offer 1.2mm galvanised steel tubing with the same external dimensions. It is roughly twice the weight and slightly more expensive, but provides a strong and accessible alternative for fixed setups where weight is not an issue.
Frequently Asked Questions
Can you build a golf simulator frame with 1.0mm aluminium tubing?
Yes. 1.0mm wall aluminium tubing is usable and very capable for a DIY golf simulator frame, especially with added padding and careful use. It may dent or bend over time from direct golf ball impacts, but it builds a functional, enjoyable enclosure on a budget.
What size aluminium tubing is best for a golf simulator frame?
25.4mm outside diameter (1 inch) tubing is the standard. The choice is the wall thickness: 1.0mm (common in hardware stores) or 1.6mm (stronger, used in the AGS RooBox Framing Kit).
Is 1.6mm aluminium tubing worth it?
For a long term setup, yes. 1.6mm is far less likely to bend or dent, keeps the frame square for longer, and adds only about 644g to a standard home frame, and through the RooBox Framing Kit it costs similar to 1.0mm bought locally.
How much heavier is 1.6mm tubing than 1.0mm?
About 36% heavier per length, but on a standard 3.0m x 2.6m x 1.5m frame that is only around 644g total, a negligible difference in practice for a big gain in strength.
Can I use steel tubing instead of aluminium?
Yes. 1.2mm galvanised steel tubing in the same external dimensions is a strong, accessible alternative for fixed setups. It is roughly twice the weight, so it suits builds where weight is not a concern.
What tubing does the AGS RooBox Framing Kit use?
The RooBox Framing Kit uses 25.4mm OD, 1.6mm wall aluminium tubing, so you get the stronger option without having to source it yourself.
Final Thoughts
Both 1.0mm and 1.6mm walled aluminium poles can build a functional, enjoyable golf simulator frame. The thinner option is cheaper and lighter; the thicker option is stronger, sturdier and longer-lasting.
In short: yes, 1.0mm aluminium poles are usable and very capable for simulator framing. But at Aussie Golf Sims, we choose to stock 1.6mm wall aluminium because it never hurts to play it safe and build something stronger.
Happy golfing!
Ready to Build Your Own Simulator?
Explore our Sim Builder at Aussie Golf Sims, high-strength 1.6mm aluminium tubing, easy DIY assembly, and everything you need for a rock-solid enclosure. Not sure what suits your space? Send us your room dimensions or book a call and we will help you plan it.
New to the idea of a home setup? Start with our guide on whether golf simulators are worth it, then come back to build your frame.