OK, here are some additional pictures showing the brackets. I also made a jig out of 1" steel pipe to bend the brackets to make the "cradle" for the PVC. I used some strapping from Lowes and bent it. I think it is about 1-1/2" wide or so. They were galvanized and I painted them black.
For the slots, I did it by hand. I have a table for my router with a fence (see picture). I just keep it pushed up against the fence and table bottom real well and go slowly. That allows me to keep it straight as it does want to roll, plus if I went to fast, it would chatter and start to wander. The other thing is my pieces were already cut and only about 54" long so I was not doing a 10 foot long piece or anything.
Let me know if there is more questions.
Thanks,
-Keith