Aluminum Router

I wonder about the "illegal" part--why? Routing in aluminum might require more power than in wood, and thus a wood router manufacturer might not warrant the router for the heavier duty.

The routing process throws off lots of aluminum chips, so eye protection is essential, and gloves are good.

OSHA.

It doesn't have to make sense.

How safe is it for the boat to sink, due to bad welding? It might be worth finding the safety test standard for grinding and allied wheels and their driving machines. See if you can carry out the test with your original tool. "Designed for" does not mean much when tool safety is concerned, they have to pass the test. If you did not have problems with bearing or tool failure using the machines, it would suggest they are robust.

GA. You might also look at a cuting tool with a smaller diameter so the surface linear cutting speed is lower. Usually this is needed for aluminum versus cutting in wood. .......Ed Weldon

GA

For the Aluminium dust, an air driven tool would be great and solve the problems with the electric motor.

It isn't uncommon for a CNC machine to use an ordinary wood router. Shops keep a stack of them for quick, cheap replacements. The usual problem, and objection, is having aluminum swarf get into the electrical bits. Take care of that, without cutting down the airflow, and you should be fine.

BTW, before carbide tools were common, we cut aluminum with a Simmons "Semi-High Speed Steel" woodworking circular saw blade. Modest folks, Simmons.

For more information about the router lookon these pages www.creneau.fr

Best Regards Libor