Need help cutting a long capsule shape on an aluminum channel

[DanielPinoy]

Hey guys,

I'm trying to achieve this cut shown below but I don't know how I'm going to do it. I've already drilled all the holes.
I'm using a 3/4 x 3/4 aluminum U/C-Channel 1/16 thick

Here's the CAD drawing:

[IMG]http://i49.tinypic.com/1zxtj7l.jpg[/IMG]

[butre]

personally, I'd measure everything out, use a drill press to take out as much metal as I could, and then use a dremel, file, or router to cut out the rest

[DanielPinoy]

Thanks! I'll try that

[ewitwins]

Do you just have a flat piece of aluminum with holes in it? If so, check and see if any of your local hardware stores will bend it for free. I know ACE does it at some locations

[DanielPinoy]

No I bought it pre-bent, c-channel

[Warlord_1011]

How about milling it?

Do about 1/4 at a time, its only ally so you should be able to do it one cut deep, if you know what i mean?

[clutch2]

Router. With a decent bit aluminum is a cake walk.

[RR_Raptor65]

You could rig up something like this for an angle or die grinder too:

[img]http://puu.sh/1xgTI[/img]

Just drill the holes at each end of the channel and start from there.