Router table to clean up edge

[Whiskeymike]

I'm making aluminum blocks from bar stock, cutting with a bandsaw. The two edges cut with the bandsaw, has blade marks I clean up on a table disc sander. I'm using high quality zirconia sanding discs and it takes about a minute to clean up the edges.

In order to reduce that time as I have a couple thousand to do, I'm thinking about using a routing table, decent sized Bosch router and a straight bit to clean the edges. I'm only looking to take a 32nd or less from the edge. This is strictly cosmetic.

Any tips on the bits I should use? Brand, size, material? Would it make sense to find a finishing mill bit that is side cutting?

The aluminum blocks are 1.5" wide by 1" tall and 1.5" by .5" tall. So I would need a bit about 1.25" of cutting length.

Any tips on how to setup the fence so it cuts relatively straight?

 

[dnschmidt]

This is a safety disaster. Trust me I cut off the tip of my index finger doing something like this. Spinning carbide at 20,000 doesn't give a damn as to what it cuts. DON'T DO THIS!!!

 

[Sine Swept]

^ agreed

I would not do this with something so small, it spells all kinds of trouble. Projectile / missing finger tips or possibly worse

 

[ez-duzit]

Instead, you need a better bandsaw setup. Mine produces a finish that looks like it was milled. Either your bandsaw needs tuning or replacement, or your blade is a POS. Should only take seconds on the sander.

 

[Quickster]

This is a safety disaster. Trust me I cut off the tip of my index finger doing something like this. Spinning carbide at 20,000 doesn't give a damn as to what it cuts. DON'T DO THIS!!!

Router shield.

http://www.mobilesolutions-usa.com/store/p218/Fukuda_Router_Shield.html

Or just buy a piece of plexi and some cabinet handles.

 

[RivennHewn]

Router shield won't work with pieces that small.

Clean them up on a disc or belt sander.

 

[gnpenning]

^^^^^ agreed

 

[dutchgray]

Or make something to hold the blocks for you so you can keep fingers well out the way.

 

[srmofo]

I'm not opposed to aluminum on a router, but the short length would prevent me from trying it

 

[dr_clyde]

I would make some sort of jig to hold the piece so you can keep your fingers clear. It wouldn't take long, and with a thousand to do could definitely save some fingertips.

As far as bits go, Freud or Bosch gets my vote.

 

[PelicanPines]

Forget the router. Agree with getting a better blade on the saw.

There is no shield that would protect you while working with those tiny blocks... also said already and totally agree.

Short of building a holding jig that would hold a bunch of blocks while you slide them past the router.... but.... I wouldn't go there.

 

[neophyte]

A titanium nitride coated HSS end mill used in the router would be a better option. The coating is to prevent galling which can be a problem with aluminum.

 

[zkling]

You are talking taking a ~30 thou doc with a 1.25" tall side mill. That's a good bite for a small mill let alone a router table. I'd look at other solutions depending on the end use of the blocks.

 

[woody 73]

As my old shop teacher use to say...use the right tool for the right job end of story. A router is used for wood, A mill is used for metal you get the idea!

 

[Indexmill]

Buy a milling machine.

 

[kv501]

Good intentions but really bad idea. Aside from the safety nightmare you're going to get atroscious galling and after the first couple pieces the edges will look worse than when you started.

 

[The Cobbler]

buy a proper negative hook aluminum cutting blade, in a miter saw & you won't have much clean up at all .

 

[Beemer533]

As my old shop teacher use to say...use the right tool for the right job end of story. A router is used for wood, A mill is used for metal you get the idea![emoji106]

I agree, but aluminum sort of blurs the line.. I cut aluminum (typically 6061) stock on my table saw and chop saw all the time. I just have carbide blades I use just for that.

You are talking taking a ~30 thou doc with a 1.25" tall side mill. That's a good bite for a small mill let alone a router table. I'd look at other solutions depending on the end use of the blocks.

I don't know why he would be taking 30 thou off in one pass? 5-10 thou would be fine for a clean up pass.

OP, I would first make a jig to hold the blocks and second use a 1/2" 3 flute end mill. Hopefully your router has a 1/2" collet?
If it doesn't, I would not try this with a 1/4" shank, especially at 1.25" depth.

Limit your clean up pass to less than 10 thou and turn the speed all the way down on the router.

 

[dr_clyde]

I've cut a lot of aluminum with a router. Pretty heavy cuts too. If you have a safe, firm setup this shouldn't be an issue.

 

[Whiskeymike]

Yes, it's a 1/2" collet. I'm going to work on a piece holder. If I could do 10 in a pass at a time, that would be awesome.

 

[RivennHewn]

Securely holding 10 little pieces of aluminum adequately is going to be a challenge.

I would not allow any of my crew to even think about doing this.

 

[Whiskeymike]

Yes, it's a 1/2" collet. I'm going to work on a piece holder. If I could do 10 in a pass at a time, that would be awesome.

 

[dr_clyde]

Yes, it's a 1/2" collet. I'm going to work on a piece holder. If I could do 10 in a pass at a time, that would be awesome.

That's a bit more sketchy than one at a time. I was thinking a sled that you have a destaco clamp on or something. Hard to say. I probably wouldn't do multiples at once.

 

[Beemer533]

Yes, it's a 1/2" collet. I'm going to work on a piece holder. If I could do 10 in a pass at a time, that would be awesome.

10 at a time would probably not be a great idea without a really solid jig.

Depending on the jig, it would probably be pretty quick to run one at a time vs trying to load 10 at a time..

This post edited by the NSA

 

[wkearney99]

If sanding is doing it well enough then why not stick with that? Wouldn't a table mounted disc or belt sander be likely be a lot less dangerous (to you AND the material) than using a router as a milling machine?

 

[srmofo]

Still have all your fingers?