A quick look at Industrial Metal supply shows they have 0.058" wall tube 
so sizes 1/8" different in od will telescope. (if not damaged)
 Onlinemetals.com is also stocking 0.058 and 0.120 wall so for the 
latter, 1/4" different in od will telescope.
 yagimech software from DX eng can yield a good feel for the wind 
strength and one can sleeve tubes once or twice (doable in yagimech) and 
the strength directly adds (only true for round and square tubes). 
Always lather up the overlap with Penetrox if you ever want to get tubes 
apart.
Of course increasing diameter wins over more wall thickness per lb of Al.
Grant KZ1W
On 11/11/2020 15:30, jimlux wrote:
 
On 11/11/20 2:51 PM, john@kk9a.com wrote:
 Correct , there is a lot of tolerance on extruded tubing and it will 
likely
require machining to fit together.
John KK9A
Ron Gorski ron-n9au wrote:
 No. The 1-1/4 inner tube will not necessarily fit inside the 1-1/2 in 
tube
because of nominal manufacturing tolerances.
Ron N9AU
  
 Have you looked at using Unistrut (actually generically called "strut 
channel") it's pretty stiff, and a 10 foot length of the standard 1 
5/8"x1 5/8" in galvanized steel is about $30.  Aluminum is about $55.
It's kind of like erector set for adults.
 There's all manner of clamps and brackets you can get for it to bolt 
equipment to the struts.
 There's a smaller size unistrut (low profile) which is less expensive 
(about 60%)
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