I have now cut about 60 feet (.040 inch) of aluminum sheet using an MDF template and a small hand router (Bosch Colt). Roll smooth and cut well. After a total of 60 linear feet of cutting aluminum sheet through all grades of aluminum from 2024-0 to 7075, inspection under a magnifying glass showed little to no wear, and the cutting tool got a little warm inside the softest aluminum . Running Blade 2024-T3 and harder at a feed rate of about 12 inches per minute, I found I could go 12 to 18 inches before pausing for a minute to let things cool. This tool seems quite useful.
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