On Tue, 30 Sep 2008 10:25:01 -0700, Tim Wescott
wrote:


Without jumping up from $200 to $2000, is there a tool that will make a
nice straight cut in a 1/16" sheet of mild aluminum?

A table saw. For 16ga material, sandwich the aluminum between two
pieces of Masonite or other sacrificial material. A saw sled will give
you something to clamp the sandwich to and make the operation much
safer, and will help if exact size and squareness is important,
especially on large pieces.

--
Ned Simmons