Using a router to cut aluminium?

You can get cutters for routers that are specifically for aluminium, youll need to watch your speeds though, and a decent lubricant such as Rocol.
 
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Of course there are a number of ways to produce slots in sheet ali, some correctly outlined by posters here; drilling, hand-sawing, milling, notching, nibbling, panel-punching, etc.

However, the OP asked about about the feasibility of routing the stuff ... it's no more difficult than working with a laminate; by temp bonding the ali to a 'wooden' base sheet a laminate is produced (as suggested in my earlier post). Observe the standard set-up rules & safety precautions (as we would anyway when using this tackle) and there is no danger of mashing the workpiece or the fingers.

We've hand-routed ali, and on a few occasions stainless steel (with the correct cutter & the speed turned down), so can confirm the task is possible.

Get an ali slot drill for a router from Trend.
 

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