The cutting of the outer aluminium profile was probably the easiest and most straight forward job, quickly completed in half a day. It simply involved large bits of aluminium (above), and large cutters (below). After talking it over with everyone under the sun, I concluded that the only effective way of getting the outer profile without any deformities or metal memory/stress issues was to cut it out of a block. Wasteful and expensive yes, but necessary at this stage in the game. A massive block of 1 inch aluminium provided the material for the part plus plenty of space for tool clearance and clamp space. The photos below explain the process much better than I do in words:
Here you can see the final part. Tabs were left on to ensure the part didn't move and smash the tool. They were eventually cut through and filled out. Two profiles were made, one normal size and one over sized with cuts locating where the profile splits open (on the visual model part of the profile slides across to reveal the battery/SD card slot.
