How would you machine this?

[AdamHeard]

Is this to lighten the part, or is it a track for something to move in?

A manual mill may do it like eric said if you can keep the vice straight. I also like Ben's idea of a table saw.

[Tapoore]

Originally Posted by Ben Piecuch

How about a metal blade on a table saw? To get the 3/4" slot you may need to rip it twice, but it should be fairly accurate. You can always plug the extrusion with some wood after the first cut to keep it straight and true. Metal blades aren't cheap, but neither are 5' travel horizontal mills...

Bengineer

That was my first thought because we have already have a metal cutting blade for our table saw, but I'm just not sure if we could get a high enough level of accuracy. I'll try this tonight on a piece of scrap.

Originally Posted by AdamHeard

Is this to lighten the part, or is it a track for something to move in?

A manual mill may do it like eric said if you can keep the vice straight. I also like Ben's idea of a table saw.

The slot is for nylon rollers to run in. It's supposed to be kind of like Bishop Wisecarver's DualVee but cheaper and lighter (the rollers won't be so "V" shaped so we won't have to make the 45-degree bevel on the edge of the slot.)

Thanks for all of the quick replies!