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I need to open a 1/4" slot down the 60 inch length of a light wall aluminium square tube. I was going to use a solide carbide spiral bit with the router mounted in the table. Does anyone have suggestions or experience with such abuse of a router?
 

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You will not be abusing the router or bit.

Keep the speed well below 10,000 rpm and a very slow rate of feed. You'll be very happy with the results.
 

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Put duct tape along the al. prior to routing. Saw this idea on the net somewhere for use when using a cutoff saw on aluminium and it made a huge difference to the amount of swarf left on the edges after the cut.


Cheers.........Sean
 
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