Thanks for all the tips guys. I may look into getting a bandsaw. A lot faster than a hacksaw anyways. We'll see, this is just something I'm trying out at this point.

As for why I'm going with 6061, a few reasons. 1) It's cheaper than 7075, so if I screw it up, I won't be out of pocket too much!, 2) From what I've been told, it's easier (at least for a beginner) to work with than 7075, and 3) 7075 seems to be a special order item only around here, while 6061 is much more readily available. I would definitely like to use 7075, but not until I'm more confident in my skills.

I was definitely thinking of anodizing as well. Thanks for the lead on what type I should go with. I wonder if anyone has ever tried powder coating? I've done this extensively with my bikes, and it produces a very strong finish, although my bikes don't go through the abuse my r/c vehicles do.

Thanks!

Chris