Low cost ways of working with aluminium for a n00b

[cdag]

Hi Stonelesscutter,

I am based down in galway, i work with Aluminum alot and its uses and treatments. I would suggest that you draw up your design in cad if you have the facility and develop the pattern [ie solidworks sheet metal] and sub out to a local fabricator. What you are describing could easily be fabbed up with one of the many fabricators based in your locality and also powdercoated - for easily less than 400 and with a greater quality than what your will achieve by yourself. I would suggest making the corners chamfered rather than rouunded as all of that can be fabbed easily with a profile cutter and press brake. Hope this helps
Best of luck