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https://rathasochenda.com/product/heavy-duty-universal-swingout-hinge-kit/Swing Out Spare Tire Carrier Universal Heavy Duty Hinge Kit Assembly | Ratha Digital Media LLC

Post some pictures

you just need to turn off supports in your slicer. If you’re using Cura, I can help you find where to turn them off.

Check out Fiverr lots of CAD designers there to help you. https://www.fiverr.com/search/gigs

Pictures of the drill press wound helpful

Cool, are you going to 3d print it, CNC it out of aluminum?

Get one of these, they work great, no skill required. https://www.sharpeningsupplies.com/Chefs-Choice-Model-120-Professional-Knife-Sharpener-P60.aspx

These my work for you: https://orangealuminum.com/press-fit-connector/

Sorry I can’t resist.

Looks great! How thick is the aluminum?

Sounds like you don’t need much force, look at camera tripods.

Making a guide block might work. Use the drill press to drill a straight hole though piece of 2x4 that is a tight fit on the rod. Slide the 2x4 over the rod, hold the 2x4 against the die until you get a few threads started.

Go to https://www.fiverr.com/search/gigs and search for CAD Drawings

Here’s how I’d do it. - Buy 6” roof flashing (25’ cost ~ $16.00) - Cut in 32 1/2” strips. - Fold a double 1/2” seam along one long edge. - Fold a single 1/2” fold on the other long edge. - Fold around a 1/2” plywood bottom, secure with tacks or screws. - Fold a seem where the ends of the...

Search for insulated oven panels. This site list 4” x 26” x 8’ panels for $200. https://www.laxengineeredsolutions.com/Colmet-4PNLMF26-p/4pnlmf26.htm

Checkout this camper build. He uses aluminum & foam composite walls. https://www.garagejournal.com/forum/showthread.php?t=466397

https://fractory.com/us/plasma-cutting-service/ list laser tube cutting on their site. No experience with them, just stumbled on their site a few days ago.

Have you considered a fold down table like this? https://www.amazon.com/dp/B07CQSSZ8P/?tag=atomicindus08-20 Seems like this would address most the issues identified above. Plus you don’t have to find a place to store the cutting table.

Use angle iron for the frame, put your sheet metal on the inside and tack weld it.

Anyone used one of these? For $17 it might be worth a try...