Panel Materials
I need to do something similiar to what you did, except it will be nothing but a flat panel at specific length and width, and thinkness to hold common toggle switches. Where do I go to get precise measured aluminum (or even pc board) pieces? Or, is there a cutting technique you recommend?
When I had access to the metal shop at work, G-jobs were pretty easy with the "right" tools and materials. When working at home, it takes a little more creative thinking and adaptation.
For making small boxes and panels, I usually use cold-rolled, galvanized steel sheet such as is used in the sheet metal trade for making ducts and flashing, etc. It's easy to cut with tin snips and bends and drills easily. There's usually a sheet metal shop around that you can get scrap pieces from. The metal is pretty flexible but, you can stiffen it up with some simple bends (see below).
As noted in the previous post, PC board stock works well as does plastic sheet material. Aluminum is nice if you have a good source and the right tools but, it can be a lot of work when you only have home hand tools. Plain epoxy or henolic material also works nicely if you have a source for it. Back in the old days, HAM radio guys often made panels from mason board but, they usually looked like crap because they usually used paint or Dymo lables on them.
I also recommend that anyone working with sheet metal get some angle iron (1" and 1.5" and the extruded stuff because it's more rigid than the formed steel angle) and cut (or get it cut) into various lengths (from about 1" to about 20" or so) and some C clamps to use for bending. You just clamp the metal between two pieces of the angle iron, with a flange protruding, using the C clamps and then use a hammer to bend the metal flange over. With a good selection of the steel angle iron and some planning, you can form some fairly sophisticated boxes and panels.
Beyond that advice I just recommend thought and experimentation. Good luck.