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First of all I would suggest using sheet aluminum... and something with like a 1/16" thickness that can be bent and cut easily but not flimsy. You can cut this easily with almost anything, but a $80 band saw would work well... I have one. It would be easy to make with MINIMUM fab skills.. only thing that would be a pain is all the measuring and fitting. ... just tedious.
And the metal you can get at any metal supplier... you just have to do a search on yahoo yellow pages.. took me a while to find one, and they typically sell in HUGE quantities, but the place I found gives me all their scraps if I want including stainless... and their scraps can be as large as 3x3'.
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