I would like to craft a slatted ventilation panel/grill like this:
The frame will be made of square aluminium tubes (25 mm side, 3 mm thick). The slanting panes will be cut of 4 mm thick aluminium sheet.
The main challenge here is to affix the panes to the frame in a nice, regular fashion. My intention is to cut shallow (0.5-1.0 mm deep) grooves on the tube sides, apply some metal epoxy (e.g. JB Weld) and slide the panes in the grooves:
The whole point of the grooves would be to direct/hold the panes in the right position while the epoxy hardens.
How do I cut the grooves?
Is there some artful tool that could save me from tedious and error-prone work with a hacksaw and file?