[JCharlton]

A vertical bandsaw is a great tool for any FIRST shop, but for cutting sheets sometimes the throat is inadequate. A shear is a great tool too, but 0.090 aluminum is really pushing it.

For under $100 you can get a jigsaw at Canadian Tire that will cut 1/4" Al (or steel) to a high enough degree of accuracy for gussets. Yeah it takes a little time, but for the low volume it's the inexpensive way to go. Our team calls it the "Loyola Waterjet".

If you have the resourses for a CNC router that may be a good route to go, or finding a company which will water/laser/plasma cut parts is also great for quality parts. Doing the jobs in-house with student work is also viable and sometimes the faster way to go.