If anyone wants to get sides cut by router or water jet and is using one of my designs, let me know and I can supply you with a profile in DXF format which most cutting shops will be able to use - it's how Jim did his.
cuyeda wrote:Is there a similar process to cut out the both the wood sides with the aluminum skins to match?
Either water jet or router will do it separately, though it's often hard to convince woodworkers that cutting aluminium doesn't need special tools.
I was discussing with someone just yesterday whether a water jet could cut them both if they had been stuck together in advance (the build process would have to be altered so that there were no screws or nails to go through from the outside): I reckon it could be done if cutting first through the aluminium and then the wood.
Andrew