Well Jeff, that's pretty much what we do at work. Then again Mil spec stuff. Personally I just don't think that aluminum is the correct material here. It's a fairly small piece that will really only be accurate if it were stamped. I think a composite part is the way to go. I'm about 45 min into the project and will be wetting out come cloth in another 1/2 hour. It will take longer to trim the part then to tool up and lay it up.