Kevin,
I keep a block of bee's wax near the table saw to help with cutting
aluminum.  Also, I purchased a special aluminum cutter for my die
grinder from the local machine tool supplier (Dixietool.com).  It has
many fewer, but deeper flutes than ones made for ferrous metals.  It
works really great on aluminum.  My experience showed that it gives a
much better finish than a carbide wood cutter does and it was easier to
control (you still need to pay attention).

FWIW,
Mark S.

-----Original Message-----
From: Rotary motors in aircraft [mailto:flyrotary@lancaironline.net] On
Behalf Of Ernest Christley
Sent: Thursday, March 03, 2005 8:34 AM
To: Rotary motors in aircraft
Subject: [FlyRotary] Re: hand router milling

kevin lane wrote:

> a regular carbide bit for wood cuts well.  the secret is to get the
> larger diameter bit , otherwise they constantly clog up.