Recently ordered the 5D tactical jig and bit set. I will be using a Dewalt DWP611. Am I assuming correctly the the end mill it uses replaces the collet system and screws directly to the router?
Also is drilling the FCG hole with the 5/32 bit perfectly fine or is it better to drill undersize and then ream? I think I've read somewhere that the actual FCG hole is actually a little smaller than 5/32 (0.15625). Also with the jig is using the router ok for the FCG hole or would it be much better to use my drill press, a Nova Viking 83700, and use the jig as a guide. With the jig do I have to still worry about the bit wondering and need to use a spot drill bit first? I've been thinking of getting a precision collet for my drill press, will probably pick up a Llambrich 4LHG5 keyless precision chuck at some point in the future if not for this. I do still need to get a Mitutoyo dial indicator so I can double check the run out of the chuck my drill press came with.
And speeds. It sounds like for drilling aluminum I should want somewhere in the 2-300 rpm speed, which my drill press can go down that low. And only need WD40 out of the can as a lubricant? Is WD40 even actually a lubricant I thought it was actually technically a water displacer?
For milling I'm finding it difficult to find the correct RPM. It seems like maybe either 13 or 15k? The Dewalt has a variable speed of about 16k up to about 27k, so I'm assuming I should set it to the lowest speed? Since I am using the Dewalt as a mill I'm guessing I should just spray a lot of the WD40 between each pass since I have no way to really give it a constant stream of spray.
I don't really have much actual machining hands on knowledge, but I do watch a lot of This Old Tony and every single Clickspring video that is put out. :) And I have used my router for some woodworking projects. I understand what is going on pretty well I think just not much actual real experience.