Does anybody know if square aluminum 6063 say 1" will slide into 1.25". The wall of the 1" is the same as the inside wall of the 1.25". May seem like a silly question but I wasnt sure if it maybe was a standard that they could fit into each other.
Look or telescoping/telescopic tubing, which is made for that application. I had more information on this on a computer that crashed, but I remember from another forum that people wanting to do what you want were guided to telescoping tubing rather than regular tubing.
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I find it highly unlikely that they will slide. They will be tight. If you can find 25mm square tubing, it should slide in tube with a 1" inside dimension (you might still have to file the corners a little). Like Dorada said, look for something that was intended to slide.