I had a devil of a time rounding the corners on 1/4″ T6061 aluminum plate when I fabricated the rear light assemblies. I decided not to do that again for the upper or high-stop plates.
I am making plates so that my LED surface mount lights have somewhere to mount to. I am rounding the corners so that they fit into the fiberglass holes from the old incandescent lights.
I ordered the metal from OnlineMetals.com. They were quick and it showed up cut exactly to the right dimension on both the lower and upper light plate orders.
I then drilled holes and drilled and tapped screw holes for the LED lights.
However, I needed to round the corners. A CNC Mill would be ideal, but I don’t have one anymore. You can see my old one here: https://www.youtube.com/watch?v=Sae6_1ZaIPw
What I do have is a DeWalt MaxXR jigsaw like this one:
DEWALT DCS331B 20-Volt MAX Li-Ion Jig Saw
Regular metal blades gum up in aluminum and then they don’t cut worth a damn. So I did some research and found that DeWalt makes some aluminum and fiberglass blades that are supposed to go through metal like butter.
DEWALT DW3755H 4-Inch 8 TPI Aluminum/Fiberglass Cut HCS T-Shank Jig Saw Blade (5-Pack)
I ordered a set on Friday and they were delivered Sunday via the US Postal Service. Prime is really handy.
They are not quite like going through butter, but they are definitely an improvement over standard metal blades that are designed for steel.