Tony - The aluminum is 1/8" thick 1 1/2" L Snhaped aluminum which you can get at Rona etc... To do the mitre cut I used my compound mitre saw and a blade for non ferrous metals.
The main purpose of the base is for looks and to hide the foam and protect the corners of the glass. I also make this one the same as mine with 3/4" MDF notched out for the aluminum so that legs can optionally be screwed in later.
Evan.
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