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Cutting metal with a router
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Avery:
If you are making big, low detail cutouts (say a couple big ovals) then I'd go with the jig saw.  This is very much one of those let the tool do the work kind of jobs.  Forcing it will just make your life harder.  Cover the top with contact paper or something to keep the saw base from scratching it up so much.

If you are making small or highly detailed cutsouts (a bunch of little stars and on big one in the shape of a guy in a space suit) rough out your shape with a drill and jigsaw and then use a jewler's saw to cut it to the shape you ultimatly want.  They're about $10-15 plus another buck or three for a pack of blades.  Needle files make cleaning this sort of thing up a lot easier.

If you are doing something thin enough you can use a shear of some sort or even a razor knife.

There's also the cold chisel, which is remarkably efficient for some purposes, though 1/8th aluminum, which someone mentioned, would tend to bog it down.
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