Everyone!
Great news! After having a long conversation with an expert on this fabrication at a fabricators about 20 minutes away from here that does top quality aircraft and other work, he was able to get my digital pictures, converted CAD drawings, etc. all set for his laser machinery. We decided on 18 GAUGE (yes, thicker) mild steel that can be painted. He recommended a paint to me (which I already use) that he said he uses heavily on durable parts such as truck brakes, etc. The gentleman is a pleasure to work with and the only one so far that knows his s***. He has to speak with his production manager (which is out) and his boss (since we're special) and promised to call me back Monday. I already know I'm going to have to spend some money for the time he has spent, as well as a quarter of an hour on setup time on his laser machine amoritized over the initial order of five sets. Cost - hell, I don't know yet - but by industry analysts that I talk to, I think I'm in the sweet spot as what I have posted on the board. If all goes as planned, I should have something done by mid next week. Then, I will be placing orders in batches of 5-10 sets (depending on cost). He also offers powder coating - though he said it's not really needed as the paint used should work just fine.
Cheers. Impatiently waiting.
- Brian