Working with Aluminum

[noncompusmentis]

Help... please!!

I need to 'alter' some aluminum trim. I can't find a substitute, so I need to recycle some old trim (it's from an old caravan door) as it has the right profiles.

Below is a picture of the current trim:


All the 'inner' grips need to be removed. I've mocked up a picture of how I want it to look afterwards:


I tried to cut a bit out with a dremel type machine with tiny cutting discs, but it's awkward and VERY time consuming. I need to do about 3m in length including some pre-formed corners.

The inside width that I need to clear is 18mm.

Any ideas how I can clear the internals out without overheating the metal?

Hopefully the knowledge of TNTTT will have some suggestions!!

Cheers
andy

[mallymal]

Router with metal cutter & router table, so you could feed it along a fence? Just my 5c worth....

[72FJ40]

First choice: Milling machine. Have a friend with a mill in home shop? A machine shop can do this, but no guess as to cost.

Not sure I would try the router. Speed of cutter and hand feeding the metal sounds like a certain danger.