Tweakers' Asylum

Any machinists on site? Q. re. aluminum stock & router bits

24.150.114.253

Hi,

I'm thinking of building/experimenting with Symposium clone isolation platforms and was wondering if a good quality high speed flush trim router bit in a shaper would work for triming the aluminim sheet (say less than .125) thick flush against the mdf layers. If not, any other good way of getting a nice edge without a machine shop?

Thanks.

Follow Ups:

Thanks to all! (nt) - AJ 16:36:29 08/21/07 (0)
nt.
RE: Any machinists on site? Q. re. aluminum stock & router bits - KLS 16:14:50 08/21/07 (0)
The aluminum bit benefits from a lubricant on it to help prevent bits of metal from sticking to the cutting edges. Kerosene is the old standby. Silicone spray lube works. Any industrial hardware stores in your area might have tapping fluids suitable for aluminum in 4 oz. or larger sizes.
It'll work just fine, provided that the motor on the shaper has enough torque. - SF tech 18:38:23 08/19/07 (5)
1/8 inch or less shouldn't be a problem. The hard part is feeding the material by hand in such a way to get a decent finish on the edge. You have to proceed with absolute conviction... If you hesitate and get a kickback, it can hurt you. Also, be aware that there will probably be hot aluminum chips flying at you. Wear a face shield and clothing that will protect your skin. You don't want any of these hot chips going down your shirt, trust me!

It can be done though. I used to cut aluminum sheet using a large plunge router and MDF forms... Not for the faint hearted!

Good luck :-)
- Not for the faint hearted is an understatement, - risabet 22:59:27 08/19/07 (0)
  I've routed aluminum and it is a sight to behold. Hot chips of Al are the least of your worries. Only do this in a spotlessly clean (no sawdust) shop or you may burn it down. Use featherboards both top and side if possible and don't hesitate as SF_Tech stated.
  
  Good Luck.
- RE: It'll work just fine, provided that the motor on the shaper has enough torque. - unclestu52 20:36:02 08/19/07 (3)
  Using a four flute bit helps a lot for control. The two flute bits tend to 'bite' and grab. I've cut up to 1/4 inch aluminum with a standard router (not a laminate trimmer).
  A fine triple chip carbide saw can also be used, again with caution and using a slow feed.
  
  Stu
  - RE: It'll work just fine, provided that the motor on the shaper has enough torque. - yotacowboy 05:42:50 08/20/07 (2)
    I've cut some 5/16" sheet 6061 with a circular saw, flipped a carbide blade around backwards, and used plenty of cutting fluid and it wasn't nearly as bad as i thought it would be. Perfect little chips and a surprisingly good cut.
    - RE: It'll work just fine, provided that the motor on the shaper has enough torque. - unclestu52 12:25:52 08/20/07 (1)
      At a naval shipyard we often used a regular table saw with a carbide blade and a dry cut to cut aluminum angles lengthwise, with little issues. The key is a slow steady feed, making sure you don't jam the aluminum stock into the blades.
      
      We used to also use a 3 inch hand held circular saw made by the Quackenbush company which generated something like 1/2 HP and an unbelievable RPM. We used that one shipboard to rip through sheet aluminum up to 1/2 inch thick (you could go thicker but the blade was a bit too small in diameter). That was one hell of a tool, and using it scared the c**p out of me. I always had to go to the restroom afterwards. It did make beautiful cuts once you got used to it, but it maimed a hell of a lot of users!
      
      All these tools were used dry, BTW.
      
      Stu
      - Have done similar stuff - Ed Sawyer 16:36:12 08/20/07 (0)
        
        In Reply to: RE: It'll work just fine, provided that the motor on the shaper has enough torque. posted by unclestu52 on August 20, 2007 at 12:25:52
        
        I've cut up to 1.25" round alum barstock with a circular saw or a dewalt miter saw, dry, with a carbide blade. Works fine. Have cut up to 1/4" or maybe 3/8" aluminum plate (and copper) with the same tool. Alum is not a problem to cut dry. Copper gets grabby...
        
        -Ed

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