ABS is easier to cut the spacer but you still need a way of doing it.
It could be done on a jig saw with a removable blade. You drill
a hole in the spacer material. Put the blade through it and proceed
to cut the straight lines.

Hi Doug, I would suggest making a template from plywood or any material
that's easy to work with, and than using a router. Makes fast clean cut.
Bulent

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Good idea Bulent. Lets check on the price and temp of
ABS sheet. Ops max operating temp 160 F. Cost 12 by 24
$25.42. About the same as aluminum.

Can you hand route 1/4 inch aluminum?

Cotton Phenolic is 250 F and about the same price.

Laminated carbon fiber. 420 F.  $297.78 for a
12 by 24 sheet. Out of the ball park. Probably
very hard on cutting tools.

Paul Lamar

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