The problem with using flat bright bar is that the process of making it bright (cold rolling) induces a lot of stresses within the metal, when you start to cut out for things like axles it can release these stresses and you end up with bananna shaped frames.
Sheet material is no longer easily available in imperial sizes so that is why 4mm has been specified and you won't get the distortion problems.
Sheared plate can have a distorted edge so the other option is to get your local sheet metal supplier to lazer or plasma cut off a couple of strips for you to shape or go the hole hog and get the profile lazer cut.
J
Edited By JasonB on 07/11/2013 18:20:46