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Try using X & Y positions for all holes. We had some older controls at a place i used to work that would randomly drill out of position if we didn’t do that.

Shear hogs are the best I've found for cutting aluminum, the polished carbide inserts leave an awesome finish. AB Tools Inc - Manufacturing High Performance Rotary Cutting Tools since 1977

I was not referring to the op's comment, I was responding to your comment saying 3 fl cutters were not acceptable for slotting. That is simply not the case.

It is just something I have always done on thicker material. I do use more 3/16 bits so you might need to reduce the step over a bit so not to over stress the tool at full depth.

When cutting 3/16 or 1/4 we step the dia over .020 with every pass. So say you are cutting a 6" x 6" square out of 3/16 6061-t6. Your first pass at z-.06 would leave the square at 6.06 x 6.06 the...

I disagree on 3 flute endmills, it is all we use we regularly pocket / ramp slots in 6061-t6 with a 1/2" 3 flute helical zplus coated at 7000rpms 50 - 100 ipm

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G64 is not a(mode), it is a cancel command for the modal command g61(exact stop) like a g80 for a drilling cycle.

Topper or robodrill make small machines that will rigid tap.

A 3 flute endmill would be better. Ramping in at 20-30 ipm at 3500-4500 rpms