Bending the aluminum arms is a pain, and keeping them in one piece is even more of a pain.
It looks like we use the same arms as DSE, and my biggest complaint about those is also the weight. 3/4" thick is way too much for our application, and flycutting them down to, say, 5/8" would really increase cost. Making our own is an option, but the 1-1/4"-48 spline broach isn't cheap.
In my opinion, you can do what you are asking. It's easy for me to say because I have FEA software to help out, but you have the section height working for you. The stress on those arms isn't terribly high, just think how a conventional 1-1/8" hollow bar holds up under similar stresses.
PM me and I'll see if I can get you some idea of what needs to be done. Time is tight for me, but I think I can help.
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Matt Jones
Mechanical Engineer
Art Morrison Enterprises
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