Finally completed the form blocks and was able to start on cutting aluminum. Glad to have progressed to the next step!
During the course of building the form blocks I kept having chatter issues with my router table, while looking into it I discovered the shaft was bent and causing the bit to wobble. I gave in, and purchased a new DeWalt dw618 variable speed which has performed far better especially after I mounted it to my welding table. Since my welding table is 1/2" steel plate it is VERY solid and the chatter issues have gone away completely.
I took a top from N3UW and bought a 1/2 flush trim bit as well, I them replaced the 1/2" bearing with a 3/8 bearing and used that for trimming my form blocks. I also found that it was the best way of making consistent holes as I would cut 1/8" undersize with the fly cutter and then tout the last 1/8 hole diameter out which left a cleaner cut than the fly cutter. The final step was to route a 45�er with a chamfer bit since I plan to press my flanges. Once I started cutting, I discovered that the bolts for the snips were scratching the material so I ground them smooth to reduce scrap. I am currently trying to ensure the layout is the most efficient possible with material prices as high as they are now..