Machining Aluminum with a router?

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need to make a few brackets out of 1/2" thick aluminum plate. at some point i recall seeing someone using MDF as a template and tracing with the router.. however that was some time ago and i cant seem to find the website again. my question is has anyone on here made parts this way and can offer me any advice?  what bits to use etc? thanks
Reply:I've used a router for bevelling plates, works great better than wood actually. I've used HSS steel bits when it's all I've had and carbide, by far carbide outlasts. Only things I can think of is watch out for vibration as  it'll kill the bits, use some form of lubricant on the bit to prevent aluminum sticking to it and don't overfeed it. I use DoALL Tool Saver but others have posted similar good results with their favorite lubricant stick.....Mike
Reply:Also use a large router and 1/2 inch diameter shanks on the cutters.  The 6000 alloys are gummy and some sort of wax/lube helps preventing the aluminum from attaching to the cutter.  Faceshield, gloves and hearing protection is a good idea.  I prefer a skill saw for all straight or almost straight cuts.  With minimum depth and care you can cut a radius of about 18 inches on 1/4 inch but it takes patience.
Reply:that sound pretty cool!!!  now I need a project to try this.   w-d 40 mis a great lude for alum.Daye
Reply:Don't get caught up in this as cool.  A word of caution.  If the router gets out of control and the bit grabs the carbide can be torn from the cutter body and go flying.  Also there is a risk of bending the cutter and the router shaft.  Cutting aluminum with a skill saw is much more dangerous than running it through a 2 by 4.  You have to be thinking all the time and NEVER lift a spinning blade or cutter away from the material.  Wait until everything stops.  I had a lunch buddy who back gouged his aluminum welds with a skill saw that had the base plate removed.  A frightening thing to see.  He still had all his fingers but I would not have even thought about using that tool.
Reply:.... who back gouged his aluminum welds with a skill saw that had the base plate removed.
Reply:well instead of using actual wood working router bits im going to use end mills that are made for aluminum. first project is actually making 1/4" spacers for intake manifold base. ill post some pics when its done.
Reply:Looks like a homebrew CNC table is in store for you.
Reply:anymore info on that? lol  Originally Posted by yellowLooks like a homebrew CNC table is in store for you.
Reply:http://www.cnczone.com/Anything and everything that you would ever need to know about making your own CNC router table on the cheap!