How to build a custom case?

[Jeff G]

Ok, for those of you who are case modders or build your own case, what tools do you use?
I'm really getting into the custom case thing, but looking for tools to make my cuts and openings look a little better. Is there certain dremel attachments or certains saws/blades that work better than others? Lots of my cuts are looking ragged due to the thin metal flexing while trying to cut, any suggestions to help make the process go a little smoother?

 

[Spotswood]

I fabricate cases exclusively using aluminum extrusion and sheeting, which cut like butter using standard/normal carbide tipped woodworking saw blades and router bits. I cut the AL sheets on a table saw and "drill" fan holes using a handheld router (although, recently upgraded to a CNC).

-Rich