[JERRY2KONE]

Yea cutting aluminum for most of us is best done with a jigsaw and then filed to the shape you desire, and finally sanding it with fine sandpaper to get it to a nice finished look. Then finally polishing it to whatever sheen you are looking for. The best way to cut a sheet into a chassis would be with a milling machine. It can be very cool if you just have a friend who has a mill that can do your work for you just by exchanging a few beers for the job.

I have never made a chassis myself, but if I were going to attempt making one I would do a nice drawing of the layout, and then trasnfer the drawing to your aluminum sheet. Next I would drill pilot holes wherever needed to make cutting as easy as possible. Finally cutting out your design with either a jigsaw, or if you can find a good blade that would cut aluminum in a scrollsaw that would be the cat's meow because of the great versitility that a scrollsaw provides. Good luck with your project and please come back and share your results with us.