Do you think I will knacker it?

[DanielW]

Got two pieces of Aluminium bar 19x45x200 mil,I need to cut an arc in both pieces for a motor to sit in.

I'm thinking using the dremel clone drill with the black grinding/cutting disc to cut away the arc almost to the arc line and then use my 1.5hp router with a two flute endmill fitted and route the arc cleanly and true.

Wouldya say I will b*gger the router?

 

[pedrobedro]

You might kill the end mill but he router will be fine as long as you don't press on too hard.

 

[brightspark]

if theres a lot of chatter when cutting it wont do it any favours thats about all

 

[DanielW]

Oh I won't be in the room where the other half is,I'll be in the kitchen.

I'll try the four flutes end mill first,better than the two flute.
It will only be a few mild skims just to make it nice and neat/level so not really taking a lot off in one go.

 

[Rig Pig]

File it out with a half round, chalk the file every few strokes to stop the swarf sticking, you will get a much better finish and far less risk of wrecking the job.

 

[monkeymark]

I'd go jigsaw for rough and file finish.

 

[Wedg1e]

I'd go jigsaw for rough and file finish.

Same here.... unless it needs cutting through the 45mm dimension! Either way it'd be a filing marathon...​

 

[Jan]

If you can't knacker it then let me have a go. I can knacker anything!

 

[DanielW]

Hah! inspirations of cutting the arc out first with the dremel clone drill and the black cutting disc.....pfffft! will take all day and lots of disc used.

Must be high grade aluminium? bollix

 

[julianf]

I would suggest what you say -

Do the rough cut however you see fit. Get it as close as possible, but dont worry about it being smooth or anything like that.

...and then do the finishing cut with the side of the router.


So, yes, basically, exactly what you say, but get the roughing cut as close as you can so there is less work to do on the finishing pass - i think this will be your key move - getting the roughing cut close but not over.

(remember how much you can bodge with a jigsaw if you dont care about the quality of the cut... ; )


You can test this by taking a slim cut on an offcut of your bar, and seeing how it goes. If its uncontrollable, or gives a rubbish finish, you know its not the way to go!

 

[julianf]

...in fact, with care, you could just grind the arc with your angle grinder, inward (disc perpendicular to the edge) slowly an carefully - that way you will (with care) be able to get very close to your line, and then just skim with the router to clean up.

 

[DanielW]

Horlicks! after cutting out the arc near to the line(bladdy hard going with a jigsaw),I found me sodden 2 end mills are in mm and me routers colletes are imperial.

Arrrrrrrgh!

 

[MattF]

If you're almost to the line, I'd go with the suggestions to file finish. Might be a bit tedious, but readily doable.

 

[DanielW]

If you're almost to the line, I'd go with the suggestions to file finish. Might be a bit tedious, but readily doable.

Only if your windbags are in good nick.

 

[DanielW]

That works a treat with the router,just taken a light shaving off as a test and its pretty good.

Can't do it fully just yet need to make a jig to keep the ally in place otherwise I may slip with the router.

Will show the piece when its done.

 

[DanielW]

Not too bad,seems the router doesn't even weep at the cuts so long as its light cuts.

Just another cut the motor doesn't sit in the arc flush but I'm happy with the progress,only hard part was the jigsaw cutting.

 

[DanielW]

I reckon any router over 750watts will do for routing ally with end mills.

 

[DanielW]

Next project....making an milling attachment for my lathe,cool

Anyone made one for theirs?

 

[DanielW]

I'm on the second piece of ally cutting the arc out for the motor mount,it seems sometimes you need to contemplate on the throne for the lightbulb to switch one.

Instead of spending the most time with the rough jigsaw cutting I have found that its much simpler to drill a series of holes around the arc(bigger the drill bit the less drilling) anyway 9 drilled holes and I can now route without touching the jigsaw.....why do these ideas sometimes come late.

 

[DanielW]

Well it works I'll give him that....can't last long though? but at least he's doing it on a bridgeport.

Wood router bits,laughs.