Image 1 shows the first Strut after it was band sawed - you can still see the rough edges - next to the original template. Image 2 shows three more Struts ready to be cut out using the band saw. Note that I've already drilled relief holes wherever there is an interior corner. Image 3 shows the 4 Struts after they've been cut out, sanded smooth and outside corners radiused using the disk sander, and then deburred using a Scothbrite wheel in my air drill.
Cardstock Template Next to Aluminum Part
Three More Aluminum Struts in Process from Scrap Aluminum
