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Have a look for flexible shaft grinders. These are widely used by
jewellery people. They typically have a 20,000 RPM 1/4 HP 110 V
motor and come with a foot control for variable speed. They may
or may not include a post that clamps to the bench top to suspend
the motor. Foredom is a leading brand but there are several others.
What is nice about the FSG is that the hand piece is compact and
light - an operator does not need to manipulate the weight of the
motor.
Make sure that the collet is capable of accepting the shanks of the
bits you intend to use.
Because of your experience, you will already know that there are
cutters that are designed for aluminum work.
I was a machinist running a Bridgeport and Lathe for 12 years, and also, I too have had a steel sliver pulled out of my eye years ago, crazy, woke up in the morning with blood coming out of my eye, the sliver was rubbing the backside of my eye lid and man, was it painful...
I have used at least 1000 barrel roles over the years but cant imagine taking 1/4, or even 1/8 of material out with them, but it has been a while.
And a tip for you as well , the family dishwasher is a great aluminum parts cleaner, just don't let the wife catch you...
Found this too, reduces the cost of expensive long shank Carbide Burs