Creating corner joint for aluminum channel profile

[ptr727]

I am trying to create a 90deg corner connector for aluminum channel profile.

I created a profile extrusion that fits snug inside the profile when 3D printed.

I am now trying to figure out how to extrude the two sides into each other at a 90deg angle?

I should look something like this: https://eztube.com/product/2-way-black-33-composite-connector/

Any help appreciated.

[davebYYPCU]

Not enough information.  If that is an insert, what thickness is the wall of the extrusion?

Left or right handed?

Edit Sketch 2, to establish the correct distance for the centre point of the Pattern, (my crystal ball gave up.).

Might help....

[ptr727]

Apologies for poor explanation.

Attaching new design that shows what I have in mind, except it needs to be hollow.

Imagine this is a piece of 3D printed plastic that connects the hollow profile at a 90deg angle.

The connected pieces need to be hollow on the inside to allow wires to pass through.

[davebYYPCU · Accepted solution]

Quick look at the new file.  Nope,

Imagine how easy your job would be if you had at least one Extrusion piece to work to as the external size reference.

Based on my pattern photo, you only need to add the corner cube, that is 

Extrusion piece height, and Extrusion piece width, with the inside corner snapped to the pattern centre point, as a start.

Decided to edit sketch 1, instead.  Did the Chamfer, but let you do the fillet.

Might help.....

[ptr727]

Thank you.