DIY Golf Simulator Builds: Should You Use 1.0mm or 1.6mm Aluminium?

DIY Golf Simulator Builds: Should You Use 1.0mm or 1.6mm Aluminium?

Choosing the Right Aluminium Tubing for Your Golf Simulator Frame

When building a golf simulator enclosure, the strength of the frame plays a major role in how stable, safe, and long-lasting your setup will be. One key factor is the wall thickness of the aluminium tubing used in the frame.

In Australia, most local hardware stores stock 25.4mm outside diameter (OD) or 1” aluminium tubing with a 1.0mm wall thickness, while specialist suppliers can 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?

Strength and Durability

  • 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

1.6mm wall tubing is approximately 36% heavier than 1.0mm wall tubing. 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 initial cost, but 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’d 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 specialised suppliers. AGS includes it directly in our framing kits for consistency, convenience, and better build quality.

Which Thickness Should You Choose?

The right choice depends on your priorities:

  • If you’re 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 Options

If you prefer DIY, can’t 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’s roughly twice the weight and slightly more expensive, but provides a strong and accessible alternative for fixed setups where weight isn’t an issue.

Final Thoughts

Both 1.0mm and 1.6mm walled aluminium poles can be used to build a functional, enjoyable golf simulator frame. The thinner option is cheaper and lighter, while 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—well, it never hurts to play it safe and build something stronger.

Happy golfing!

Ready to build your own simulator?

Explore our RooBox Framing Kits at Aussie Golf Sims—high-strength aluminium tubing, easy DIY assembly, and everything you need for a rock-solid enclosure.

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