the dremel is a great way to mess it up, since it wants to dig to one side. I think the next best thing to a mill would be a pneumatic file.
it takes way too long to do this (w/o one of those tools) to be profitable or affordable but hopefully I'll inspire someone to take the plunge (and they like their results)
I removed about 50% of the material w/ the dremel, 45% w/ half round bastard file, and then I squared the edges w/ 1/4" round mill file.
I have spent a lot of time w/ a file in my hand (mostly shaping gun stocks and removal of rust pitting), but this is the first time I've done much w/ aluminum.
It is easy to remove material and polish but not very forgiving if you slip
thanks guys, it is nice to hear good feedback after spending that much time on it :)
Their are some slight asymmetries...they might show in better photos (but I'll post them anyway). You really have to move it around and closely inspect to see them though.
I was thinking it looks like a rook, too.
I started accentuating the bezel crenelation to match the tail, but now that you mentioned it, maybe I should flatten it instead to make it more 'rook' like.