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If you need to ask what materials and hardware to use that gives me a clue you shouldn't tackle a project like this. I'd follow the previous advice. Another serious consideration is the geometry you're trying to acheive. Having said that even some of the best outfits like Heidts, Speedway, Stock Car Products etc use seamed (ERW) tube for their tubular arms. I would make my own from a 1020 DOM (seamless) tube (not pipe). Good luck.
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