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I recently saw a sitewhere they made some nice waveguides like that from two flat pieces of sheet aluminum. They machined the slots on a CNC router (!) and then bent them on a sheet metal brake, and finally TIG welded the two halves together. Might be cheaper to simply buy one, unless you've got access to a shop...
As for procuring the aluminum, I've scored some pretty exotic chunks of metal at local recycling yards, they usually charge by the pound.
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