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Cleanly Cutting Metal for CP Under/Overlay?

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Necro:
Ok, I'm finally there.  Initial demo CP has been tested.  Art is semi-designed.  I now need to get the tools to put together my CP.

But...I've hit an issue.  Based on this old thread (http://forum.arcadecontrols.com/index.php?topic=85827.0) I know what to do...but...

How the heck to I **CLEANLY** cut the sheet metal for the overlay?  Snips don't seem like they'd be clean and a jigsaw definitely won't be straight.  A circular saw is asking for something to shoot out and kill me. 

I have other tools (Rotary Tool and Oscilating Tool) but neither seem appropriate either.

Any suggestions?

Xiaou2:
Cleanly cutting sheet metal usually involves a metal cutting "Brake".

 You may be able to use a fiberglass cutting wheel on a tablesaw to get a decent result
however.

 If you had no other choice, you could cut it with a jigsaw, then clamp the thing to a
straight edge guide, and use a grinder to remove the excess.

 Do not try to use a dremel.  You would need about 8hrs and 60 cut off discs.
 

Necro:
Hmmm...ok.  This makes things more complicated.  I'm going to put art over it...so...maybe the washer+bondo option wil provide enough strength.

Or thin plexi.  Didn't want to to the plexi route though.  Might have to.

bkenobi:
Find a metal shop.  They can cut the CP in about 2 seconds and should only charge you a few $ for the effort.  They will either us a break or a band saw.  Either way, they should remove the sharp edges for you so you don't cut fingers off when playing!   :o

ubiquityman:
I'm guessing the traditional non-automated tools are the best choice in this case, but if you are making things in volume, some business have laser cutters that can cut 1/2" steel.

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