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@BrickMan
RE: sheet metal bending. have various size hand operated presses, and a very very large hydraulic bender (18tonnes/inch?) with various toolings for it. So can bend just about anything.
Material wise, just had an epic clearout at work, and most of the small (free) offcuts of alu sheet (3/5mm) have gone. Have a piece of ~5mm alu sheet approx 300x400mm sat here (should be able to do 2 or 3 items?) thats supposed to be 6000 series of some sort.
I think you'll find 5mm for the 180mm sized rotor pretty damn weighty.