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I originally found a local place that specialized in aluminum but after a year of them constantly putting of the design work I decided to work this project on my own. The price list that comes w/the software showed aluminum to be almost 5 times more expensive than steel. Also, using wire EDM was necessary for cutting the tight and accurate curves for the teeth. I designed it to be professional-grade and tough -- quality. I hate cheap tools!!!!!!!!!!!! I'm a computer programmer, not a mechanical engineer nor machinist (I just play one in my garage ;-) I wish I had the education! I also don't have easy access to a shop so I have to get by with what I can find and emachineshop is the only place willing to do one-offs, as well as batch jobs, for joe-shmoes like me. Plus the free CAD software used to allow one to design their own stuff is very cool for me! Yes, there are definitely much better applications out there but for what this does, I'm not complaining! Like computer programming, I'm sure there is more than one way to make this tool. Hey, got any need for an apprentice where you work? :-) Toby Erkson -- Portland, Oregon -- http://www.icbm.org/ '72 VW Squareback Darksider, 5-speed, 2007cc, rag top '95 VW Jetta 2.0L, CHE tranny w/Peloquin LSD, 270¼, TT Chip, SCCA Solo 2 EP#3 '73 Porsche 914 2.0L WIP; '81 Honda Gold Wing, 1100cc, stripped ----- Original Message ----- > Toby, the second version is a beauty! Wire EDM and ground, swoon. A > little overkill? Would a chunk of any plate (even Alum.) and a CNC mill > could get you there. Maybe water jet cut. ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ List info at http://www.vwtype3.org/list | mailto:gregm@vwtype3.org ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~