A new processing route for the consolidation of mechanically alloyed aluminum powder has been investigated. The attrition milled and degassed powder was processed by a fairly conventional PM method consisting of a double cycle of cold pressing and vacuum sintering. A systematic series of experiments were conducted to find optimum values of compaction pressures and sintering temperatures. The final consolidated compacts have relative densities and mechanical properties comparable to those obtained using well-established hot-working processes. In addition, this method allows the elimination of the degassing heat-treatment step. Improvements in ductility are achieved by using purer aluminum powder.