I've read a few threads on this topic, and I know that a router is the wrong tool for working brass - even so, I have a fairly simple project I'd like to try. It's also the wrong tool for aluminum and I've had decent results with a few simple projects.

I need to accurately cut a small shape in 1/32" thick brass, and then drill/countersink a number of holes. I have the CAD drawings, the gcode, and I have a solid woodworking CNC with a Porter-Cable 2.25 HP router.

I can securely fasten (screw/bolt) the sheet stock to a solid backer, attach that the my table and then cut my pattern. If I go ahead and attempt this, what size/style bit should I use, what router speed (10K RPM is lowest), and what kind of feedrate and cutting fluid?

My gut feeling is to use a small diameter bit (perhaps 1/32" - 1/16"), run the router at 10K RPM, move at a slow rate, and take a very light depth of cut. Make several passes to cut the complete pattern. Perhaps some compressed air or fluid to keep things cool.

As far as drilling the holes goes, maybe spot drill them with the same size bit, and enlarge and countersink on my drill press. Or I could chuck the correct size mill, drill the holes, and then come back with a V-bit and do the countersinking.

Does this make sense? I'm sure I'd be better off taking this to a machine shop, but it's kind of a test part and I'd like to try it myself before paying someone else to make it for me. A proper CNC mill is on my list of projects, but won't happen anytime soon.

Thanks,

Steve