I've offered to help a mate out by machining some pieces of 75x4 SHS for him.
They are outer sleeves with 19mm slots and a section removed from the side to allow it to clamp over another piece of SHS with an 18mm bolt.
Pieces are approx 150mm long.
Not a precision job but he needs a dozen of them and I'd prefer not to take a whole day making them!

Thinking I might just grab a 19mm or 3/4" endmill to cut the slots, flip the part 90deg and use the same cutter to rip the section out of the back side leaving a small tab on each end so it doesn't spring/collapse on me. Finish off with angle grinder and cutting disk to remove the tabs and flapper wheel to round the corners and deburr.

I'm interested in how you experienced guys would tackle this from a more production perspective.

Outer Sleeve.JPG

Steve
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