maybe a cross brace on the back tacked on so it keeps its shape over time???out of flat bar or something??

just thinking out loud here but better yet if i do a cross brace on the back out of square tubing that could hide all my wires eh??? would be clean no??:):)

A lazer cutting shop will be the best bet http://www.google.com/search?q=laser...ed=0CCkQtQMwAA
, as for the size I would not go over 1/4" as it will just be overkill personly 3/16" would do it for me also if you get it lazer cut it wont twist or bow out of flat, your only going to be supporting a few kilo at max right?

I get one off items laser cut for work all the time. I would guess Laser Equations in Calgary would charge you around $200 for 1 peice.

Depending on what thickness of material you need, probably .125" a sheet metal shop or hvac shop might be able to cut it for you cheaper

It might be easier to make this out of plywood and basic hand/power tools. Definitly cheaper!

A 1/2" or 3/4" square tube x brace to hold the shape and the wire's would be simple light and look clean, drill some holes at the end of the tubing, attach your hanging wire and you are all set. Easy job for any good welder.

use aluminum its easy to drill and it doesnt rust

This maybe a cheaper solution...

http://www.reefcentral.com/forums/sh...1552033&page=3