Punch or cut a 1/2" deep x 0.125" wide side-slot in 0.080" 5052 AL

[BT Fabrication]

Cutting something that thin with a slitting saw won't work, it will vibrate and bend too easily.

Punch press/ironworker is the best way.
Cleveland tool steel makes custom punches for things exactly like this, might be a couple grand to get one. But will take seconds per part to do it. Just like punching holes, I can punch 100 holes in the matter of 10 minutes.

They also make a punch for this exact purpose. would just need it custom ordered.

Ripping Punch and Die

Us a ripping punch is used to elongate existing holes or to notch material.

www.clevelandsteeltool.com

check out all there youtube videos, there are some in there that have custom flat punch setups.

or this page of theres.

Louver, Rod and Custom Die Sets

Flatten or bend rods, create louvers or let us design a custom die set to improve your productivity saving you time and money.

www.cstmanufacturingservices.com

 

[michiganbuck]

QT: (They will only be doing these about once/week and it's around 50-100 week).
A higher quality radial arm saw feeding the saw in the away direction with an air cylinder with an oil spray might be good.

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