Sometimes the simplest thing is the most elusive. We've been looking at the answer in a number of pictures and even the Pin Vice handle is half of the answer, although that isn't a bad idea but would require a fair amount of down force but that could be remedied too.
I think it was Ed before that drew up the cad drawing of the unit with two large hard rubber wheels that the aluminum would be passed through and a corrigated bands in the middle to make the corrigated impressions.
Now lets simplify the whole unit by just having two gears, with fine meshing teeth such as the groves on the pin vise handle, that would have a tentioning devise on one side and a hand crank on one of the gears so the aluminum could be started and cranked through or between the two gears or drums and the impressions made in the process.
As far as the Aluminum stock, possibly soda can aluminum could be used?
A new Model railroader, Matt who is also a neighbor and interested in Model Railroading, his dad has a complete machine shop and Matt is pretty well versed too I'm sure so I'll have to run the idea by him.
Problem may be solved?