Aluminium Milling : 5 Steps (with Pictures) - Instructables
MATERIALS. Aluminium [aluminum] sheet, mine was 5mm thick.. Off cuts of MDF or ply for jig. Some screws. TOOLS. Electric router, I use a 1/2" router though a 1/4" should do also. High speed steel [HSS] router cutter for wood, I used a plunge cut one with cutter profiles on the bottom as well as the side, width to suit the milled slot.. Screwdriver. Cordless/power drill