With care and patience full-size sheets of aluminium can be cut using this method. Create a long fracture-line then progressively bend the sheet from one end to to the other.

Router End MillBits for Aluminum

The metal-folder is made from two right-angle sections of metal. My folder is made from aluminium but "angle-iron" is okay.

End millfor aluminum

With the aid of a straight-edge and a sharp knife "score" BOTH sides of the aluminium sheet. This weakens the aluminium and creates a "fracture line".

Place the "fracture-line" over the edge of a table and bend the overhang SLIGHTLY downwards. Flip the sheet over and repeat. After a few "wiggles" the sheet will fracture along the cut-line leaving a clean break as shown in the above photos.

Now slip the aluminium sheet between the two angle-s and roll the bender forwards while exerting downward body-weight pressure until the fold is 90 degrees.