Hi,
Let me guess..you a MUSE fan? Anywho, ive made a couple of guitars now clad in aluminium, its alot trickier than you might think. The back is easy, the top 1/2 is glued on, the bottom 1/2 screwed on (to allow access to the wiring). The front is easy... glued on. The sides are a real pain in the ass. You have to make a jig to glue the sides on else you get really, really crappy joins with the front of the guitar. With the length of aluminium needed, you do the sides in two stages, one length runs from the strap button behind the bridge arround to the bottom of the neck pocket. The other from the strap button to the end of the cutaway bu the neck pocket. Aluminium is really workable with, files are fine to make a nice neet job of matching the aluminium to the sides of the guitar. After filing this will still leave a little sharpness that can be taken away with 600 grit w&d paper... used with with soapy water.
To make the pickup/neck pockets a router will do the job with no trouble at all, just take it slow.
Hope this helps.
