Found picture (see link) of jig and router for making foils - why didn't I think of that?
Cherubs used to have a video on this, but I couldn't find it to link it.It started off something like "Welcome to Foil Club. The first rule of Foil Club is you have to talk about Foil Club".
Developed & Supported by YorkSoft Ltd
Merlin Rocket Owners Association