[Rick 427 Cobra]

A little late for you Jeff, but for straight cuts, try using a table saw or a Skil type saw with a straight edge. Use a carbide blade. This goes super quick and accurate. You can polish the edge with a file or belt sander, or just use "as cut". You can cut aluminum that is several inches thick with a carbide blade. Sheets are a breeze. Use hearing and eye protection as the "sawdust" goes everywhere. Just as in wood, more teeth gives a better cut. Hand work is for odd shapes. If you have good patterns, you can knock these out very fast.