Evan, thanks for the comments. I’m still feeling my way through milling aluminum so any insights are welcome!
Thanks for the tip on the height of the router, I’ll keep that in mind. I had to change it out recently. And, of course the replacement was out of tram. It occurred to me there is some slop in the mount ring when the bolts are loose, why not shim that with aluminum foil? A lot easier then the other way. Two layers of foil in the front, bottom between the router body and ring in my case. Tighten bolts, back in business, 5 minutes.
I forget on the mill, I’ll see if I can dig up the info. I know it was expensive but each flute has 4 faces so you can rotate them as they wear and eventually replace them. So, a lifetime mill.
I’ve gotten a lot of mixed messages in my research about lubricant. AND coated mills. AND number of flutes. Etc. So, I approach each particular cut as simply as possible. 2 flute carbide mill, start with slow feed rates, shallow doc. And progress from there.
At this point in my attempts at cutting aluminum almost every cut is something I haven’t done before. So, I practice cut in wood/plastic then scrap Al if possible.