This weekend I'll be making some buckle/cleat combinations a la andersj's really nice work:

I just got in some 3/16" 6061 T6 that I'll be carving up.

I've worked aluminum a little bit on my bike, but that was mostly polishing or just removing a tiny bit of material. This will be my first time cutting from scratch, so I was hoping for any pointers anyone thinks would be useful.

I've got a Dremel tool with various appropriate bits, a good drill, a grinder, and I'd like to pick up some type of sandpaper/emory cloth that would work well.