Corner radius on 5052 aluminum

how picky is the radius? if it's picky, line them up and buy yourself an external radaii cutter and run them through the milling machine, should be able to do 10 or so at a time, shouldn't take that long, and the end product will look a hell of a lot better than a belt sander

-S

Indeed. Will work GREAT with a horizontal miller and either a radius cutter or concave tool. You can stack a shitload of them and run em though, spin the stack 90', repeat, repeat and so forth.

Or make a die and use a Diacro style kick punch to round the corners. Might take some money setting up the die, but I think .250 should be doable.

Id say..it depends on how many you have, and how close the tolerences are. Any good punch press could do the job with the right tool if you have a Bunch (as opposed to Many )

Gunner Every normal man must be tempted, at times, to spit on his hands, hoist the black flag, and begin slitting throats. H. L. Mencken

How about pressing your wood router into use? You'll have to keep aluminum out of the motor unless it's air powered, but wrapping it in a T-shirt does the trick.

buy a corner rounder from a trophy supply dealer