Milling aluminum??

[BMF Machine]

I've used a router and router bit on aluminum before too. It works in a limited way. Your drill press is definitely not up to the job.

If you use a mill with a router bit, turn up the speed and keep the feed rate slow.

jp

I have used a router for chamfering edges of huge alum. plates at my day job? After a lot of filing and sanding, I was able to ship the part without puking?

A file will clean up the mess ya got now, and a lot of time and a file you could do all the edges nicely? Alum. cuts like butter with a good Nicholson hand file. Then orbital sander, then 3M buffing compound. It will gleam again!

Now, I just go out to my shed and use my HAAS VMC; or well not in two years anyway, but it is there if I need it, production sucks? but it does pay the bills.