03-22-2018, 06:41 PM
Mine turn out like Brian Y's pic above. I use an EP Armory jig ($40), a Harbor Freight trim router and a Home Depot ΒΌ" HSS straight router bit and plenty of transmission fluid but I take my time and don't hog out lots of material on each pass. End mills appear to be on the fragile side from what I've read, and I've found that HSS cuts aluminum fine without the brittleness of carbide.

