The question is, how to cut the slot in the U-shaped flat bar?
Came up with IMO a cool way to attach that U-shaped aluminum flat bar fork (mentioned in my prior post) to the wide piece of aluminum flat bar that will be used as the skate wheel fork. Just cut a slot in the bottom of the U. Stick it on the wide piece of flat bar. Then drill a small hole for a bolt at the very bottom of the U. And then put a bolt through the hole and squeeze the bottom of the U together. The fork can't go anywhere. It could be enhanced simply by cutting very short slots in wide piece of aluminum flat bar, and it would be rock solid. I will include a pic since it's probably not easy to understand even with a wordy description.
I guess a bandsaw might be useful to cut the slot in the U-shaped fork, but I ain't got one. It would probably need a thick/odd blade anyway, The slot needs to slide as snugly as possible onto the wide piece of aluminum flat bar. And some some super glue will keep it from any microscopic movement. It might take some time to cut that slot, but I have time (and lots of hand tools).
I suppose a hack saw might do, with the U stuck upside down in a vice. But that would just get it going, the slot would have to be widened. Using some wider blade saw might help, slowly and very carefully.
Thanks.