A few days ago, I was asked about how I made my aluminium pickguard, here is a quick overview of the tools I use, it might interest unskilled beginners such as I was one year ago. So I work on 1,5 mm alu plate, and I start with cutting roughly with a jigsaw (with an alu blade), then more precisely with snips, then large flat file to finish with small files with different shapes for the details. I drill the screw holes with a small screwdriver (I like it because it's quite slow and easier to control, I'm not good with too powerful tools - for the same reasons I gave up grinders or Dremels that always do more than I expect...)
A sanding sponge is a good way to start the sanding, then thin sandpaper used with water - then I finish with polishing wheels mounted on a drill. It's quite primitive but it worked so far, and each time I'm getting better at it! I hope that I will manage to do some engraving in the coming months...
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