Well it took me so long to finally do them that my original post got archived.Thank You to mattyboyr6 for the recommending the undercoating stuff, looks like its going to work out pretty good. I tried Plasti Dip from Lowes but it ended up peeling off pretty easy. They are not the best but I did say alot of $. I even get quick enough release, two screws and its off.
I actually got the aluminum from work, 3/8" scrap pieces. I used a band saw to cut out everything except for the round edge inside the wakeboard rack. For that I used a 1 1/4" drill bit. I put a sanding disk on my grinder to clean up all the band saw marks. Lastly I took a random orbit palm sander to all the surfaces with 60 grit paper to give it the final appearence. The clamps i made on and end mill, a bit more work.