ShopBot Desktop router up for the challenge?

[Fusion_Clint]

I suggest you find a way to make room for a machine that will do what you need. Specifically, having the ability to cut your own rails. So I suggest an X or Y axis of at least 36 inches, so that you can do an entire rail without repositioning the piece.

I like our Velox, so in your position I would seriously look at the VR2536 with a 3 HP HSD spindle. http://imgur.com/a/sXwSB

At least look at the http://shopbottools.com/mProducts/desktop-max.htm but I would be leary of the 1 HP spindel.

A spindle is significantly quieter than a router on these type of machines and gives you a way of controlling your tool speed(RPMs). You will need to mount some type of coolant system compressed air and/or a mist system. You can't be recutting the same chips over and over, so compressed air to clear the chips is a must. These single flute tools from tools today do a great job on aluminum and clear chips pretty well. http://www.toolstoday.com/p-5801-sol...uter-bits.aspx

You can build your own enclosure and/or get a vacuum hood. https://www.youtube.com/watch?v=rrKKsYCb8Tg

I suggest you get something you can grow into, once you start your own machining I doubt you will want to do less.