An aluminum block machined on a manual mill to fit inside a length of C-channel. The stock was squared up, sized to the channel's inside dimensions, and chamfered along its edges so it seats past the channel's radiused inside corners. Mounting holes were drilled and counterbored for flush fasteners.
On the mill
Layout dye was used throughout to mark material for removal and check the fit as the part came down to size.
Chamfered edges
The chamfers clear the inside radius of the channel so the block sits flat against the web and both flanges.
Fit in the channel
The block was test-fitted repeatedly until it seated snugly, with no rocking or gaps.
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