I could go for 1:1 ratio with the HK50, that would mean 18'500 lossless, does that make you happier? And yeah the angled edges are on the 'to do' list when I have done the CAD for my project.
If I can all the 2mm pieces will go to grade 6 as the Grade 2 is a little bendy.

Hmm with the Alumec, I could mill it down. It would take a while but I could get it to exactly 16mm. As an Alumini I can go back to uni so I could have all the pieces milled and finished to exactly 10mm or what ever it may be. Much better fit that way to!