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Grab one of the £40 dremels from the argos ebay, you could drill two holes with a hand drill then use the metal cutting discs to cut the flat sections with the dremel. Bit long, but totally DIY-able.
Even better if your laser cutter will etch the guides for you for when you cut.
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as @pdlouche suggested.. or you can drill several holes along the length of the slot and just file the remaining material off.
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Maybe some post-processing might help?
pdlouche
MisterMikkel
Emyr
@moocher
left hand one didnt last long. sheared off soon after hitting the mildest of offroad.
The other one held up better, but has cracked through in one place.
They could be made better, so they hug the fork closer, plus of course could be made thicker. I think casting or moulding would be the way to go, but I dont have access to that.
Aluminium plate suggested upthread would perhaps be the way, although I dont have a good way of cutting the strap slots.
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