Dremel and bit recommendation

[What's_nitro?]

Can you afford a bandsaw? Even a small one will do aluminum just fine. I've never tried to "Dremel mill" something before but it sounds like it would take a while. Plus you would need a guide of some sort. Unless your hand is bionic so it can withstand all the torque from cutting and is also perfectly stable for those straight cuts. As far as which attachment to use, a milling bit any larger that 1/8 woud require a very strong and steady hand and none of the bits I've seen for sale with the Dremels are made for metals so they wouldn't last long. I have had some success with the fiber-backed disks as opposed to the aluminum oxide ones. They don't seem to get caked up as much when cutting soft metals.