2.5 hours
I wasn't really looking forward to working on these things again, but I finally got them done!
The process I think, after making three of these now, is this. For the ends that need to be cut off, first drill a 1/4" hole in each corner, then use a dremel cutoff wheel to connect the holes. Leave as little excess material as possible! Then clean up the edges with an angle grinder flapper wheel, then files, then a scotchbrite pad.
For the slots, drill a bunch of holes slightly smaller in diameter than the width of the slot, then connect them and smooth out as much as possible with a dremel carbide cutter... thing. Then smooth everything out with a small file.
These parts took forever but in the end they turned out alright!
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