UPDATE
After looking at lots of options and my capacity to fabricate in AL I have decided to go with a sand casting. Currently I'm working on a the design for the form. I have CNC capacity resevred to mill a 1:1 pan out of a block of MDF for trial fitting before I cut the form.
An inital extimate is ~$300 for the raw casting which will be cast with additional material on the flanges to allow for correction of any casting errors.
I plan on having the form ready to go to the foundry in a few weeks.
