I have a Solution for you Peter. Get a job so that you are earning money, then you can pay the one company that has said they can make them for you what they are worth.
check out Rigidized Metals in Buffalo NY. they dont have the pattern you are describing but they do have similar things and they know exactly how to do this. Ridigized Patterns Complete Details
If you were willing to make a slight change to the material requirement, this product has the profile you are looking for, and it is readily available...
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