Cutting a groove in Aluminum

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roddyama said:
1.) You can blind drill and tap into the back of the 3/8” plates. It can be tricky because you’ll have to be careful not to break through the face of the plate with the tip of the tap-drill. You will also need to have a good bottoming tap (a little hard to find in the smaller thread sizes). A bottoming tap, or bottom tap will have threat cutting edges right to the tip of the tap.

It should be done pretty easy as I was blind tapping 1/4" aluminum heatsink to mount devices. Yours would be 3/8" so it's not a problem at all, #6 screws should be enough. If you use both screws and glue, 2 part epoxy would be fine, it also fills gaps better then crazy glue. After glueing you can sand the edges and you'll barely see it's done out of two pieces. If applicable, you can also use potentiometers and switches to hold both panels together.
 
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