At Nelsons CNC, we regularly machine custom aluminium end caps for aluminium fencing projects where standard off-the-shelf options simply won’t work. This project required custom caps to suit angled aluminium extrusions, with each end cap CNC machined in-house using a precision interference fit designed for a tight and secure installation without welding or glue.
One recent project involved manufacturing custom interference fit aluminium end caps for Pelican Panels to suit their “Beaumont” fencing design - a modern architectural style featuring 50x10 aluminium uprights cut on a 45 degree angle.
Because each aluminium section was cut on a 45 degree angle rather than a standard straight cut, the open end needs to be capped while maintaining the sharp architectural lines of Pelican Panels Beaumont design.
Machining End Caps to Suit Angled Aluminium Sections
This project required a custom-machined solution specifically designed for:
- 50x10 hollow sections cut on a 45 degree angle
- A snug interference fit
- Consistent sizing across multiple fence sections
- A clean finish ready for powder coating in Monument
The finished end caps were designed to install firmly into the aluminium extrusion by tapping in with a rubber mallet until firmly installed.
Because the aluminium sections were cut on a 45 degree angle, these were not a standard flat-top cap. Each piece had to be CNC machined to match the exact profile and angle of the extrusion so the finished fence line remained consistent across the entire project.
Why Interference Fit Matters
With architectural fencing and gate fabrication, fitment matters. A loose cap can shift during installation, leave uneven gaps, or create inconsistencies once powder coated. For this project, the caps were machined with a true interference fit so they locked tightly inside the aluminium section during installation. A true interference fit also helps achieve a clean, architectural finish by allowing the cap to install neatly and consistently into the aluminium extrusion.
For projects like Pelican Panels Beaumont design, consistency across every panel matters. A precision-machined fit helps:
- create a seamless finished appearance
- maintain consistent alignment across repeated panels
- sit cleanly within the extrusion profile
- preserve the sharp lines of the angled fencing design
At Nelsons CNC, all our aluminium end caps are CNC machined rather than cast or multi-fit, allowing us to machine to exact internal sizes to ensure a precise fit, every time.
Designed to Suit Pelican Panels’ Beaumont Style
Pelican Panels’ Beaumont design features 50x10 uprights with tops cut on a 45 degree angle in a modern “bladed” architectural style. The design appears throughout their fencing and gate range in Monument powder coat finishes.
The angled cap design needed to visually match the sharp lines of the fencing profile while maintaining a practical fit for fabrication and installation.
The result was a clean integrated finish that complemented the overall Beaumont fencing system.
Australian Made Aluminium End Caps
All machining for this project was completed in-house at Nelsons CNC in Queensland using CNC machining centres designed for repeatability and precision.
We regularly manufacture:
- aluminium end caps
- angled end caps
- press-fit hole plugs
-
base plates
- custom machined interference fit solutions
- custom size end caps
for fencing manufacturers, fabricators, builders, architects and commercial projects across Australia and the USA.
Working With Aluminium Extrusions
One of the biggest challenges with custom aluminium fabrication is that not all hollow sections are identical. Internal dimensions can vary depending on wall thickness, supplier tolerances and corner radiuses.
For custom projects like this, accurate measurements are critical.
We always recommend supplying:
- external dimensions
- wall thickness
- internal measurements where possible
- corner radius details
- sample offcuts if available
This allows us to machine a cap that fits correctly the first time.
Looking for Custom Angled Aluminium End Caps?
If your project involves aluminium sections cut on an angle, architectural fencing, custom gates or non-standard extrusions, we can machine a custom interference fit solution to suit your application.
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Pelican Panels Beaumont angled-top fencing design can also be seen throughout their fencing gallery and custom fencing ranges.