I have had good luck cutting alumimun with a table saw or skill saw as has my uncle, see 1/3 B-17. He has cut 4" blocks on a table saw by cutting half way from each side. To slow the saw down to help control heat build up, use the next size smaller blade, i.e. a 8" or 9" in a 10" saw. A good carbide blade works if you do not build up heat as this will chip the carbide, not a problem on thin materials. Boat builders use saws for cutting aluminum. As for routing, there was a EAA Hints for Homebuilders segment showing the process in which they cut wing ribs. Use gloves, long sleeves, hearing and face protection as the chips are hot. You may have to promise the wife you will replace the carpet if you track those sharp chips into the house.