Our door was damaged in a storm, and it broke the cast aluminum connectors that hold the profiled framing together. They're not available separately, so I had to make new ones.
Donor material is the front bumper from a MINI Cooper, which happened to be the correct 6mm thickness. All cut and filed by hand. My proof of concept was an aluminum rain gutter nail.
Attachment 8819.
Attachment 8820 Attachment 8821