The replacement AA6-187X2X2 1/2X5 stock came from Vans.  Took the Dewalt friction saw and cut the HS-1008R from the stock making the cut about 1/8″ from the finish width dimension (1-1/2″ and 1-21/32″ respectively).  Then loaded each part into a vise and used a jig saw to cut the proper depth (1″).  After that I used the 2″ 36 grit wheel in the die grinder to grind down to just proud of the finish dimension and used the 6″ 7A 3m Cut and Polish wheel to smooth out the grinding marks before finishing the parts on the other end of the bench top grinder with the 6″ EXL wheel.  All that is left is to drill the two parts and they will be done.