That machine you pointed to (I looked at the pictures on page one, but didn't read all 100+ pages of that thread) has unsupported round rails that will have a hard enough time making an accurate cut in wood - the cutting forces will cause it to bounce around a lot. I don't think it would do a very good job at milling aluminum. For that, even the best, most rigid wood routers have a difficult time holding tolerances; something like that kit really isn't designed for it.
Shop around and find some good square-section linear rails with ball-bearing trucks that you can screw down to something fairly massive and very flat. That will give you your best shot at the rigidity needed to handle aluminum. If you really can't tolerate backlash, screws are the way to go. You can get precision-ground or precision-rolled ballscrews that are pre-loaded to reduce backlash, or use acme screws with spring-loaded anti-backlash nuts. Rack and pinion systems generally need a certain amount of slop in them in order to work, although I've heard of some that have dual pinions that are spring-loaded against each other to eliminate backlash. As I recall, though, they were pretty expensive.
Andrew Werby
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