router for cutting ally

[kiwicar]

as the title sugests anyone tried putting a milling cutter in a router and using it to machine ally? or even just a normal router bit?? I want to cut some 1" square "windows" in some 2" by 3/16 wall thickness ally tube and not having a mill this would seem a posable way of doing it.
Mike

[sidecar]

as the title sugests anyone tried putting a milling cutter in a router and using it to machine ally? or even just a normal router bit?? I want to cut some 1" square "windows" in some 2" by 3/16 wall thickness ally tube and not having a mill this would seem a posable way of doing it.
Mike

A lot less technical way of doing it that should work would be to mark out the hole then carefully chain drill it keeping inside the lines, then file it out to the final size by hand. A bit of wet-un-dry to clean it up and Bobs your uncle!

Your probably looking at 20-30 mins work per hole. (I wouldn't want to do too many this way!)

HTH,

Pete

[ihatesissycars]

Grinder with a thin cutting disc.

Router should work though if the bit will fit it and you can spin it at an appropriate speed.

[Ian Anderson]

Jig saw with a metal bit! (Make sure the piece is well clamped and not a lot of pressure on the blade)

Then tidy up the edges with a file or powerfile / belt sander

IAn

[Paul B]

as the title sugests anyone tried putting a milling cutter in a router and using it to machine ally? or even just a normal router bit?? I want to cut some 1" square "windows" in some 2" by 3/16 wall thickness ally tube and not having a mill this would seem a posable way of doing it.
Mike

I would drill some corner holes in the right place then join 'em up with a jigsaw and clean up with a file. Use a new high speed steel wood blade and plenty of WD40 or paraffin. I've cut 1" thick ally plate with a normal jigsaw before.

A router will do it though, if you have a jig or set up to keep it in line, but use a high speed steel cutter (HSS) rather than carbide tipped, as it usually holds a much sharper edge and cuts better.

[JSF55]

Grinder with a thin cutting disc.

Nope there not intended for that, they "may" snatch and shatter, there intended for stainless steel, ready the blades, i'd go for the chain drill and hacksaw method, or jigsaw, or if u can afford it a little cut off saw like machine mart sell, john

[kiwicar]

thanks folks
I have quite a few to do, at least 8, so the chain drill method would be a pain (though I have not ruled it out) also the drill a 7/8 hole drill out the corners and file it out method. Don't think I'll get the jigsaw in as it is a 1" square hole. I think I'll have a go with a HSS 1/4 inch bit I've got.
thanks again
Mike

[katanaman]

use an inch hole saw and file the corners out. If you need it really accurate then use a 22mm hole saw and file. You could even use a blacksmiths drill the right size and file. Should only take you 5 mins a hole.

[ian.stewart]

See if you can locate a square drill, I kid you not, they exist

[kiwicar]

Hi Ian
Got a set of morticing chissels, they drill square holes, but in wood. they would not work on this.
Mike

[ian.stewart]

Heres the theory behind it,
http://upper.us.edu/faculty/smith/reuleaux.htm
I did use them when I was an apprenitce, only because I doubted an old fitter when he told me they existed, and because of that I had to drill square holes for a day.

[Paul B]

thanks folks
... Don't think I'll get the jigsaw in as it is a 1" square hole. I think I'll have a go with a HSS 1/4 inch bit I've got.
thanks again
Mike

Am I missing something here? You simply drill four holes, one in each corner of where you want the hole, then join them up with a jigsaw cut. Or, you drill each hole halfway along each side, and cut outwards to the corners, but the result is the same. Believe me, I have done a lot of cutting and fiddling about wiv metal over the years.

[kiwicar]

I like that alot, very clever . My only question is how do you control the orientation of the hole in the work piece.
Mike

[ian.stewart]

you clamp on a template