insane:
Huh that's an interesting idea, I happen to have a bunch of that aluminium extrude and the nuts and bolts - just need some 90degree parts.
2020 might be a bit thick? Would you make a big enough jig for the whole router to ride inside it, or just the bit/busing? I usually make my router jigs out of 6mm MDF (or 3d prints) and use a router bearing bit so the bit rides on the jig rather than the router or bushing guide. Then you also don't have to worry about offsets between jig and bit.