Re: Cutting Aluminium Sheet.
For non-radio reasons I have a plasma cutter. It's a brilliant tool (bad pun) on mild steel running with compressed air. On aluminium, the finish is less good, but it improves a lot if it is run with argon.
wooden templates can be created for commonly used sizes and shapes of holes. A plunge cut in the centre, slew the torch out to meet the template, then take it around the figure and watch the middle of the hole fall out. Sand to finish.
David
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Can't afford the volcanic island yet, but the plans for my monorail and the goons' uniforms are done
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