I need to replicate some brackets in a repair project and would like to get some ideas on how to do it. The first problem I encounter is once the planar shape has be cut out of 20 gauge ss it needs to be drilled on both ends to accomodate an AN3 bolt that will have to align nicely through these two holes once wrapped around a forming mandrel that will allow a snug fit onto a 1.0 inch strut or spar. If the wrap isn't exactly centered and square, the final hole locations will not allow the bolt to align square to the bracket plane. If I had a mill I could maybe pull this off. I have a drill press with a mediocre X/Y vise. (yes, I am looking through this forum...I am currently on page 32, nothing I could find yet). The photo attachment shows one of these brackets installed on the 1.0 inch trailing edge spar. The nut end involves a 10-32 rivnut that needs to line up with the 3/16 hole on the bolt head end.
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