[mickmate]

Hi Bob, I'm about ready to finally start cutting some ally meself. I'll second the vote on a plasma cutter, I don't use mine much but it is an awesome tool. If you want straight cuts I use a square or straight edge, radii use a trammel tool or just freehand along the sharpie line. They are a little pricey for limited use. Rule of thumb is you want an amp per 0.010". My 50 amp will cut .500 or 1/2". Have you tried the bodymans high speed air saws. I have also used a wood saw with carbide and lotsa WD40, it works but not on the noise end of things. We'll definetely talk more about the ally panels for our projects.