Originally Posted by
Greeves
Look around before buying MDF, you should find some ultra-light MDF, I just went through all this at work, got a new router 3 weeks ago, it's a multicam 3000 series with a 33 HP vacuum, well standard MDF don't work well even with a 33 HP pump, the ultra light works OK on .040 Aluminum or thicker as long as I keep my feeds down under 200 IPM. With my old router, I would use a spray adhesive to glue .020-.125 Aluminum to a sacrificial, I used a product called corex, it's about $10.00 for a 4 x8 sheet. With this setup I would cut with a .125 SF Upcut spiral bit 18,000-20,000 RPM @ 75-100 IPM, .250 SF upcut Spiral bit 18,000 RPM @ 102 IPM. 102 was as fast as the machine would go.