Help!!

[meika123]

Need a little advise again fellows. I have to cut a 16" circle out of .250 #6061 aluminum. I was going to use my router with a circle cutting jig to do this. My question is: I have a "New" 1/4" straight cutting router bit with double fluted carbide edges. If I take it slow, and don't try to hog my way through, will this not work? I have used different style bits before on thinner gauge aluminum, and it worked fine.
Let me know your thoughts, please.
Thanks,

 

[jimwill48]

Might work, but my suggestion would be to make several small plunge cuts. I have a small metal lathe and mill and a full 1/4" cut would be a pretty good bite. I usually only take .010 at a time. If it was me I would get a 1/2" end mill and use that rather than a router bit. You can get it from any supplier (enco for less than $10.00) and then would run the router at about half speed, AL likes to be cut at a fast speed but too fast and it will tend to weld it self to the bit...a good cutting oil doesn't hurt either

James

 

[meika123]

I would James. I always take small cuts at a time. Wouldn't dare try to cut it all at once. Beware of Shrapnell, right.
I'm in Yadkinville working, but live in Advance. What is close to me in the line of industrial supply houses-any ideas?
Thanks

 

[jimwill48]

To be honest really don't know since I order everything mostly from ENCO. I have put in a page from their HOT Deals catalog with end mills. I have a code for free shipping for a order of over $50.00 (not hard to do).

JW

 

[Ray Martin]

Could you use a jigsaw with a fine metal blade? It could be mounted in a circle cutting jig much like a router iig.

Ray

 

[LeeNC]

Some sound advice so far. A small cut depth for each pass will be critical. Removing heat will be your biggest issue IMHO. You may want to pause after each cut to let the AL and the bit cool. You may also have issues with chip removal. Does your router have a vac attachment? The airflow and chip removal would be helpful. It would be a good idea to clean out the vac incase a chip was hot enough to star smoldering in the vac. Not likely, but possible.

LeeNC

Edit. Enco and some of the other metal working catalogues sell solid stick (like a wax crayon) for cutting AL when a liquid lube is not practical.

 

[FredP]

I have routed aluminum and it does work OK however it aint for the faint of heart! wear goggles, not just safety glasses, goggles and a full face shield wouldnt be overkill. long sleaved shirt wouldnt hurt either! A jigsaw would be a better bet with goggles. ya cant replace your eyes and metal bits go in directions you wouldnt believe!

 

[Ray Martin]

Could you use a jigsaw with a fine metal blade? It could be mounted in a circle cutting jig much like a router iig.

Ray

This shows what that Ray guy was talking about http://www.ronhazelton.com/howto/lazy_susan.htm

Ray

 

[Alan in Little Washington]

I would first cut it out with a jig saw and fine blade very close to the line then use a router, with either the circle jig or an mdf template and a bearing/template bit to clean it up.

Or take it to a machine shop!!!

 

[jeff...]

Should work - but I think I would take it to a machine shop and have them throw it on a Bridgeport.

 

[NZAPP1]

If you are going to do it yourself I would order a 1/4 single end mill from McMaster Carr if you order it Friday you will have it Monday at the latest. I would use all of the safety precautions that Fred has laid out.

 

[scsmith42]

Last year I made a new aluminum instrument panel for my Cessna. It wasn't .250 thick - more like .125, but the principle's are the same. The panel featured an aluminum sleeve inset into it to hold a portable GPS unit, and I used a router to mill out the flange area for the sleeve.

My recomendation is similar to others.

First, use a jigsaw with a circle jig to make your rough cut. I'd shoot for .250 - .500 larger than your final diameter.

Once you have your rough cut, switch to a router - also with a circle cutting jig. You can use either a carbide or HSS straight bit - my preference is carbide. You will need to keep a lubricant on the bit, otherwise the aluminum will adhere to it. I use Tap Magic - the alumimun tapping formula. You will want to use this with the jig saw as well, otherwise the blade will gum up with melted aluminum

Be sure to wear safety goggles, take small cuts (.050 - .100), and keep in mind that when you remove .050 you're reducing the overall diameter by .100.

Scott

 

[Bas]

Last year I made a new aluminum instrument panel for my Cessna.

Scott, sometimes I think you're the Martha Stewart of what I'll refer to as "power toys". So what do you do in your spare time, practice how long it takes to disassemble a Howitzer? :rolf:

 

[scsmith42]

Bas, when I was a young lad someone told me that "he who dies with the most toys... WINS!" I thought that sounded pretty good, especially when one substitutes the word "tools" for "toys"...

Re what I do in my spare time..., why I lurk on the NCWoodworker.net!

Scott