Thanks for more info on the Rotozip, Xion. It looks like a good tool to have - but I'll be looking at divorce Florida style if I bring any more stuff into the house right now.

Graeme - thank you so much for your detailed explanation. Lou keeps telling me I need a scrolling blade - I can' seem to readily find one for cutting aluminum. (and, I didn't understand the part about being smaller from front to back, as opposed to being thinner - duh, yeah, I am such a novice). I think my best attack strategy is to drill out four holes in the corner and connect them. Just have to get the drill press setup, because that's the best way for me to get the holes right.

Again - thanks all. I know I'm not building parts for the space shuttle here, but it's important that I learn to do it right. I have some ideas for future builds that will incorporate my learnings with this build.