You machinist types probably already know this, but I found out today that using a disc grinder on aluminum is more trouble than it's worth. The metal is soft, so the disc gets gummed up and needs to be cleaned often enough to make it more work than it's worth. On the up side I have relatives on my wife's side of the family that have a full shop setup for aluminum (e.g. CNC, computer controlled lathes, etc.) and I may be able to get my headpiece machined to spec for little or no financial outlay.
Yeah, aluminum is different to work with- loads up disks and files quickly.
Great you've got a shop avail for that, too.
BTW: seems that tea cup has gotten fuller as you go along, rather than emptier...