I've got the shaping pretty much done.
By using my complex tool
from the post above I was able to cut the groove I needed. With the metal rod chucked into the flex shaft on my Dremel all I had to do was hold the piece straight and press it down onto the file while it was spinning to make my cut.
[ATTACH]59016[/ATTACH]
Here it is placed back into the body of the switch with the shape I desired.
[ATTACH]59017[/ATTACH]
I think that the overall shape is pretty good and isn't too far off from an Alco switch.
Now I need to prepare the other faux switch!
MORE TO COME!
[ATTACH=full]59016[/ATTACH]
[ATTACH=full]59017[/ATTACH]