Aluminum sheet metal stock of varying gauges is inexpensive and one of the few items I’ll acquired from mass retailers. It may come scratched (see sanding) and will likely be out of tolerance, but don’t sweat it.
Jigs & templates
Absolutely build a jig or two and do as much assembly as possible outside the chassis.
Practicing
Practice jigsaw techniques on aluminum stock matched to the same gauge as chassis itself BEFORE attempting on the chassis. Get the technique down.
Chassis AC inlet
DIY chassis
- Out of scope considering how inexpensive and well-made aluminum Hammonds are
- Requires a panbrake to bend; attempting any other way (e.g., with a mallet) isn’t recommended (see that guy who tried and tossed it)
- See Uncle Doug’s DIY chassis and embedded DIY panbrake
- Rivet together or, better, spot-weld (Hammonds are spot-welded)