How to build pneumatic costume wings   Step 4: Make the Wings
So with my 1-square to 1 foot ratio, I cut the pieces with a
hacksaw. Aluminum is pretty easy to cut this way. To make the
hinge holes 'correctly' you want to use a drill press so
everything is a perfect 90-degree angle and all the holes fit
nicely.  But what I HAD was a drill. So I carefully employed the
old Mark I eyeball, and did the best I could. Just mark off with
a sharpie and make your holes as perfectly vertical as you can.
It can be a good idea to pick up a metal file to take any sharp
bits down. Nobody touched the wings, but you never know.  To
prevent a lot of the trouble associated with imperfectly
vertical drilling, I put a washer in between each member when I
bolted them together.  (Important note: I used steel nuts and
bolts. Steel and aluminum will corrode if kept in contact with
each other due to their 'galvanic number'. In practice, this
probably won't affect a normal hallowe'en-only usage for several
years, if at all)  Once the