That's nice work for using hand tools. Care to elaborate a bit on the process you used?
Aluminum cuts very easily with carbide tipped blades. So, here is the tools used-
Chop saw with carbide tipped finish type blade (more teeth)
1/2" drill , you will fry a 3/8" drill with the hole saws.
Hole saw set in 1/8" increments
Drill bit set
Carbide cutters for die grinder, or high speed drill. Use for cleaning up inside of holes once hole saw is used.
Step bits to chamfer mounting holes
Measuring and marking tools
Upright belt sander. Bolted like parts together and rounded ends and side finishing so they are perfectly symetrical.
Small router. I used a 1/8" round over bit to round all edges. Routing is very easy.
Metabo burnisher with flap/fleece wheel to leave brushed finish.
A 20 ton brake. Not done yet, but ends of lower rear piece need to be bent over to make mounting flange.
I am about 8 hours into making these pieces, so it certainly isn't fast. But if you figure cad time, cut time, and price, and i already had all of these tools, well, lets just say it gave me something to do. Lol.
A big word of warning. If you are cutting the materials on a chop saw, if you go too fast, or do not have your work piece stable enough, the blade will grab and violent shit will happen very quickly. Hence the need for a fine toothed blade. DO NOT attempt small pieces and hang onto it with your finger tips, like I do. Lol.
For small pieces, always cut off of a larger piece. Don't try to make a small piece smaller. It puts your hands way to close to the blade and if it twists even the slightest amount, the blade will catch and you will be surprised how much stuff can happen in 0.0002 seconds!
Other than that, it is just patience and planning.