CMS Raceway Cover Elbow

Our rocket has a composite raceway that runs down most of the length of the rocket. The end of the raceway was originally designed to also be composite, but due to issues with the layups, this part had to be made from aluminum. This part was very thin and had some very complex curves. At first glance, this looks like a part that could have been made from sheet metal with some adjustments. However, we did not have access to the machines needed for this, so the part had to be machined via window machining. I squared a block of aluminum stock and formed the part inside of this block, connected by some tabs to the stock. After flipping it over, the tabs were strong enough to hold the part in place during machining. I then used a vertical bandsaw to cut the tabs and filed them away.