Let me know what you find with respect to router bits. It would certainly be a lot easier to get straight edged cuts using a jig.

I'll have to take a look at that, too. I used my jigsaw, and it was certainly fast, but, probably due more to my own paranoia (you can always make a hole bigger, but you can't make it smaller) than to the blade wandering, I had a lot of clean-up filing left to do. I have a nice Porter-Cable router, so maybe next time....(although, thinking about it, the router runs such high RPM, not sure there's any bit that wouldn't seriously overheat even in soft metal. Hmmm)