This was going to have a little welding in it, but I changed my mind. I was going to make it out of half inch and build up the top part with weld, but in the end I just whittled it out of 3/4 stock, instead. These are mounts to attach some areo bars to a pair of bicycles.

Started with 3/4" x 2" 6061 T-6 extruded bar.

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Carve out one side.

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Flip it and do the other side. Bore the holes and profile the part out.

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Flip again and drill, tap, clearance, and counterbore a couple of holes. Profile the ends round.

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Flip and scoop out the top. Drill and tap a hole.

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Here they are mounted to the bars.

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Test fitted on some handlebar tubing.

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I'll probably give them a nice glass bead blasted finish to smooth out the machining marks. Although first I have to clear some junk away from the bead blast cabinet, and I think fix some air fittings on it. Shop maintenance never ends.