Plastruct makes 99% of what I need. I did notice a bit ago that the structural shapes section goes further than what I thought so now I need to go back and make sure I didn't miss it. I will take you up on that offer if you don't mind a long print.
Dividing the column is pretty much the only way I see an FDM doing this job well. I'm glad to see someone using it in practice. I'll probably make myself a little jig to assemble columns/I beams if I go this route. That way I can clamp them good and tight.
