[mrmetooer]

Hi All,
Novice here looking for the best (easiest?) way to create a 1/4" notch in aluminum tube. see photo.

The tube is 1 inch square with 1/8" walls aluminum 6063 T5. the bar length can vary up to 8 feet long.
The notch is 1/4" wide and just under 1/2" deep. the botton of the notch needs to be rounded.
I will need to do about thousand pieces initially, so ideally i would like to line them up and notch a couple in one run.
please suggest your best method. I'm willing to spend, but would like to keep the bank standing.

Fire away.
thanks in advance.

[djr76]

1/4" carbide ball end mill, use mist or flood coolant to prevent chip welding. setup in a vise with a stop.

[Tom-AMS]

dado / form blade on a radial arm saw