went to the computer shop today and asked the guy behind the counter for and old mother board.
took it home and cut a piece off. I then put it on the grinder wheel to remove all the contact points and electronics so it was smooth on both sides.
I then drew the shape I wanted on it and cut it with a cutting wheel on the dremmel. I sanded to the exact shape and attached to the round servo wheel. Finished by making the two holes for clevises.
chuck is right. this stuff is tough stuff.. and easy to work with.. and light weight.