A woodworking router can be used on aluminum, as can a table saw.
Clamp your work piece securely to a sturdy surface and wear correct safety equipment.
The chips will be flying at high speed and will be painfully hot.
Kerosene or Diesel Fuel make good cutting fluids to keep most alloys of aluminum from sticking to cutting tools.
Brush a thin coat of cutting fluid onto your workpiece before you start, and add a bit more as necessary. A little
goes a long way.
For working aluminum, a jigsaw plus a metal-cutting blade is extremely handy.
A Sawzall with a metal-cutting blade gets a lot done quick.
An electric hand drill and a set of drill bits is a necessity.
A set of rotary rasps are incredibly handy for shaping aluminum.
A small drill press allows holes to be consistently perpendicular and takes a lot of the labor out of drilling holes.
Last year I had the good fortune to buy a Hardinge horizontal milling machine for cheap:
It needed a LOT of TLC, but now is fully functional. Removing metal is now a lot easier for me.
The year before last I bought an old (1918) Lodge & Shipley lathe. It was greasy and dirty, but a dozen hours' work had it shipshape.
It looks something like this:
With the economy in this terrible slump, used metalworking tools are at record low prices. Craigslist, eBay and similar are loaded with bargains.
SAFETY GLASSES are critical whenever working with power tools, and HEARING PROTECTION is often necessary too.
There's an incredibly helpful forum for such things here:http://www.chaski.org/homemachinist/