Below is a CAD drawing of a Sedona aluminum block. It has routes for the neck pocket, a center area for the body wood pickup routes, and the tremolo route.
The block is made from 3/4" 7075 aluminum plate. Here the plate is mounted to the CNC and the neck pocket is being milled. A router will cut aluminum using an end mill, but it is very slow, the depth of cut is only 0.03" inches and the rate is only 030 inches per minute. And it is noisy. The aluminum foil surrounding the jig is trying to catch some of the swarf, or aluminum chips that end up everywhere.
The tremolo route is next.
This is the aluminum plate after the neck and tremolo routes.
Then the main outline cut is done.
Here is the block after the main outline cut finished and has been cleaned up. There are small tabs holding it to what is left of the aluminum plate. These are cut away with a Dremel tool.
After cutting away the tabs.
The completed block after drilling and installing the tremolo studs.
The lower section of the block interferes with the volume pot. To fix this, I'll mill a section of the block away.
The finished bloack, with the tremolo studs weighs 12.2 oz.