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Try using a 2 flute cutter with aluminum. It will do a better job of ejecting chips than a 4 flute.

-Nate

Your spindle speed is too fast. Try something closer to 400 rpm using a cutter that big on plain carbon steel.

You should pick up a copy of Machinery's Handbook to use as a reference for speeds...

There is a post with some nice pics at:
http://www.cncfusion.com/phpBB2/viewtopic.php?t=81

It's an X3 though, not an X2. They did a really nice job though, and it may give you some ideas for...

I have a 6" horizontal/vertical rotary table on my X3, and it's as big as I'd go on my mill. The 6" is likely too large for the X2.

I'm in the process of gathering everything to do a CNC Fusion deluxe kit conversion to my SX3.

I got my steppers and power supply from Keling (www.kelinginc.net). I went with a 400 oz-in motor...

Thanks a ton for all of the info on thie Hoss! You've caused me to start gathering parts to build something similar for my SX3. :)

Bob - Your mods look good. One question... Is the 1/4-20...

I thought high-helix end mills were designed to work specifically with aluminum?

I'm not doing any CNC milling yet (although I am gathering parts to convert my SX3). I'm new to milling in general, but I've only been milling 4130 so far. The metal that I use for a given project...