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21-04-2020 #1
Well, it's correct that aluminum can be cut with a wood blade and many of us here do exactly that on a table saw with material upto 20-25mm thick, it's also possible to use a handheld wood router to cut out pockets, etc, if you have big enough balls and a little experience. Again several of us have done this with great success.
What thickness aluminum are you talking about.? If it's just thin stuff like 2-3mm and all your doing is cutting out holes and shapes out then it's very easy to use a Jigsaw and a drill.
If you want a little more accuracy and repeatability to your holes or shapes then I would suggest you make Jigs out of say MDF which is easily worked and shaped then use a router with a bearing guided cutter.
Or ask someone on a forum like this if they'd like to cut you some parts.!!
If you could show us a picture and give us some more details like material thickness etc then could advise better.
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