Machining Aluminium with router

[johnny max]

Hi All.
I.v been asked to machine Tee slots in aluminium box section.
The slot is 8.5mm wide, 75mm long and the tee is 30mm long.
Box is 50x50x4mm. Could I machine this with a normal straight fluted
router bit in a router.
I.v used a router a good bit making my bird setup.
What ye think?
Regards Johnny

 

[T0rnado69]

if you used the correct cutter, then maybe yes.
but the big issue is keeping the router steady,
and it not trying to shoot off in the direction of cut when the cutter bites.

proberly why metal is machined on a mill, with it locked tight in a vice.

 

[cocker]

Go for it , I tried routing some 2mm stuff .
It wernt pretty but it was funny trying to follow the lines .

 

[the snooper]

don't think id like to try that, its bad enough on some wood

 

[addjunkie]

Drill the ends and use a jig saw file up, less likley to go pete tong

 

[Chris Stevens]

Hi All.
I.v been asked to machine Tee slots in aluminium box section.
The slot is 8.5mm wide, 75mm long and the tee is 30mm long.
Box is 50x50x4mm. Could I machine this with a normal straight fluted
router bit in a router.
I.v used a router a good bit making my bird setup.
What ye think?
Regards Johnny

If you dont have a mill, wonder why you have been asked to machine metal?

 

[julianf]

If you dont have a mill, wonder why you have been asked to machine metal?

Eh?

People find out you have a soldering iron, and want you to fix their pocket calculator.

To the clueless, surely having a "workshop" allows any and all material manipulation possible!

: )

 

[slim_boy_fat]

Eh?

People find out you have a soldering iron, and want you to fix their pocket calculator.

To the clueless, surely having a "workshop" allows any and all material manipulation possible!

: )

Agree. Folk tend to ask/bring me all sorts of things from lamps to lawnmowers to see if I can fix them - so I do, others less so.

Sometimes I just say "Sorry, I don't have the things to fix that without major work - buy a new one."

 

[Chris Stevens]

Seems to me trying to cut a tee slot into material only 4mm thick is going to be difficult/impossible even if you have a mill?

 

[rtbcomp]

I don't think it's a T-Slot in the drill-table meaning of the word.

Sounds more like 8.5mm x 75mm slot with 30mm long slot T'd off it.

A diagram would help.

 

[Chris Stevens]

If its not a tee slot, then I guess a rough job would be possible with a router, but would have thought drilling and jig saw, final finishing with a file would be a better way to do it?

 

[johnny max]

If its not a tee slot, then I guess a rough job would be possible with a router, but would have thought drilling and jig saw, final finishing with a file would be a better way to do it?

At present there are 12 pieces to do. Which I will cut out with router if possible.
There are more to be done so a mill is in order.

 

[cocker]

I should think if you jig it all up one slot at a time I'll work .
Be aware though they there will be quite a bit of fine aluminium swarf flying about and it will get every where .

 

[Pete.]

I reckon you could do it with a couple of jigs, some goggles and a good set of ear defenders.

 

[hotrodder]

Routing aluminium is pretty common albeit not so much manually, as said with jigs/fences/templates to help control the thing it works OK. 'Regular' TCT bits for wood do work but it kills them relatively quickly and as soon as they dull a little things go south quickly. Everything within a 5 mile mile radius ends up covered in aluminium glitter and if you aren't paying attention and accidentally (or purposely) attempt climb cutting and/or too heavy a cut (reaaaallly light cuts are the order of the day) expect the thing to kick like a hundred mules. Hard enough to bend tools/spindles and/or ruin your day

If we're talking quantity then i'd be getting a price to get them water/laser cut personally

 

[johnny max]

Well lads
Got to make up two jigs. One for long slot and other for the cross slot.
Took less than a mil each pass got to cut out one in a scrap piece 1st.
All looks good just have to hold the router very steady and firmly.
Thanks for all the advice.

 

[Wendelspanswick]

Well lads
Got to make up two jigs. One for long slot and other for the cross slot.
Took less than a mil each pass got to cut out one in a scrap piece 1st.
All looks good just have to hold the router very steady and firmly.
Thanks for all the advice.

What about using the router mounted in a table with a fence.
The reason I mention it is I have an ancient Makita 3600b router and it's a beast of a machine with no soft start, it's a lot easier to manage it in a table then to try and use it freehand.

 

[anto44]

I used to do this regularly on extruded aluminium door frames to make slots for the locks to fit into. I used normal wood working router bits. I used a jig that held the work piece solid and had 2 guides that router sat between to guide it.

 

[cocker]

What about using the router mounted in a table with a fence.
The reason I mention it is I have an ancient Makita 3600b router and it's a beast of a machine with no soft start, it's a lot easier to manage it in a table then to try and use it freehand.

Don't do that , it's even scarier than holding the router .
As you let the workpiece down onto the cutter it'll grab and go Pete tong real quick .
Funny as , after you've counted your fingers and found the missing bits !