The router worked fine with the Aluminum - but remember, I was just removing a thin edge of material. The bit I used with Aluminum was a
Flush Trim Template and Pattern Plunge 2-Flute Carbide Tipped Router Bit with Ball Bearing, 1/4-Inch Shank.
And, for those of you who missed it, I'm using a variation of the Window Guide written by CyberDruid - check the Sticky Section for Guides at the top of page 1 in the Computer Cases section.
Enough yapping - here's what happened at the end of the day:
There are a couple of small areas that will need a little work, but all in all, better than I expected.
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