If lightness is key, couldn't he fab something up from a roll of tin foil? Uber light, and easily tweaked to get a precise fit.
If you cant find anyone, I could be of service. Do you have a computer 3D model of what you made? I have a 3D scanner if not and full machine shop capability.
Sadly....I'm guickly learning that the cost for making these one offs may not be worth it. Looks like I'll have to come up with another way to mount the motor.
If I did it on a 5 axis, factored in scanning, cleaning up the scan for modeling (which admittedly I’m not amazing at so I would farm it to someone I trust who’s more talented than I with that part), material and tooling cost plus run time on the machine I would venture to say it would hover around the $1k mark. But to be fair I would be using aerospace level equipment and time isn’t cheap to clog up even 1 machine that isn’t for flight parts. Plus I would have to do it on one of my 2 days off a month. Maybe someone here can hook you up, model it and do everything in their spare time as a passion project for pennies on the dollar.
Yeah....these parts won't be going on the space shuttle. I was looking for someone that has the equipment or access to and likes to tinker as a hobby. I would supply the material and pay them for their time/labor.
@GRH just got a shiney new CNC..... http://forums.13x.com/index.php?threads/machinists-need-opinion.340603/ If you were closer I might be interested in this, but the logistics make it a non starter for me. Lots of luck.
Would be cheaper to plasma cut the flat sections and join them with some tubing. That could all be done with basic hand tools and a tig welder.
I've got a Bridgeport and a rotary table and enjoy carving on aluminum drop me a pm. It won't be cnc but doesn't look to difficult.
I got someone that wants to give it a shot. Thanks to everyone that offered help and/or their services. WERA beep saves the day again.