Flyscreen aluminium extrusion corner joint - repair/replacement

Our fly screens frames made from aluminium extrusion were broken as they became brittle. Finding a replacement internal plastic was impossible for me, so I designed a replacement. 

To remove the old plastic I found two methods worked. 

1. Butane torch to heat the plastic so it wasn't as brittle, then fold the edges away from the aluminium and slowly remove it.
2. Hammer the plastic remains in further to the extrusion. (I resorted to this after not being able to remove all plastic and found it was easiest). 

Once the plastic is the removed, you just need to insert the new corners and re-rivet them in place. 

It's the strongest my doors have ever been!

Printed in PLA (although PETG would withstand the heat for longer)

30% infill

Max printer speed settings.