We might as well finish this post. Sorry for the delay but I became a new grandfather since my last post.
I need to mention that the Aluminum that was purchased was 5052 in 080. Plenty stiff for this project so no beads or flairs were needed..
After all of the pieces were fabricated it was then check for lay out. Cutouts for fan locations and clearance.
Then installed Nutserts and welded the project to life!
Then added a makers mark.
All went as planed and my friend was very pleased.
Fan layout.jpg
Nutsert tool.jpg
Nutsert back side.jpg
SIL puttin it together.jpg
All fits.jpg
Final.jpg
Makers mark.jpg
installed.jpg