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Blade selection, blade selection, blade selection. The bandsaw should be fine for cutting aluminum, as well as a jig saw or recip. What you'll want to do is get the appropriate blade for the saw. You'll need to find a blade made for "Non-Ferrous" metals such as Aluminum and Copper. Here is a link to a jig saw blade, that is made for cutting Non-Ferrous metals. http://www.toolauthority.com/product_in ... ts_id=3830 Hope this gets you going in the right direction if you still need the help.

Although both suggestions so far are reasonable and may work just fine for you, another thought is blade selection. Bosch offers a jig saw blade that is made for non-ferrous metals such as aluminum and plastics such as PVC. It is designed in such a way that it is not supposed to “load up” thus reducing the amount of heat created and making quicker cuts. Only $8.75 for a 5-pack http://www.toolauthority.com/product_in ... ts_id=3545