Low cost ways of working with aluminium for a n00b

[Doddy]

Interesting challenge!

I'm not sure Ali will be your friend in this game because it is so soft. Also, it doesn't "work" well - forming 90 degree bends can crack the material unless you have a silly large bend-radius. Maybe steel sheet with something like a scroll-saw with a metal-cutting blade would offer a cheap entry level capability?, next your challenge would be to finish the product - powder coating or similar, can be outsourced.

If you're doing one-ers, then as Jazz says ask for someone with suitable machine to do the cutting for you; if you're planning to do more then you need to be a bit more realistic with your machining requirements and costs.