I need to widen a slot

[bad_idea]

I have a slot that is about 1 1/4" wide by 6" long in 1/2" thick steel, I need to widen it to 1 1/2" wide. The slot is nicely machined and I would like it to look nice (not hacked) when I am done. I have a mag based drill and I was thinking of some way to use an end mill in the mag base to get decent results? Any better ways? I really don't want to use a burr bit or a cutting wheel if I don't have to. Can you rent a portable milling machine that could be used for this task?

 

[Drew_flux]

looking at your thread title, so many rude answers,so little time. As for your problem, no idea.

 

[racingtadpole]

The mag drill idea could work if you have a lot of patience and set up some sort of guide. You'll need to only move the drill a small amount each cut otherwise you'll end up with a serrated edge.

A gutsy plasma cutter would probably get it done with reasonable results too.

 

[brucey]

Sorry for the newbie post but yes you can rent portable milling machines etc Google on site machining etc

I dont know where you are in the world but linky here to some piccies and the style of machines etc

http://www.bljinsitusolutions.com.au/situ-machining

Yes they are basic but if you are in the middle of nowhere or the job is too big take the machine to the job They are very effective too (yes i have used them)

Good luck mate

Bruce Back to lurking now

 

[kevinstj]

You would be much better off finding a small local shop to widen the slot for you. It would cost a lot less than the cost of renting a machine. I don't think the mag drill would really work. I don't think you could get it rigid enough.

 

[454ragtop]

Don't know of any portable mill rentals, doesn't mean they don't exist, just never seen one. Don't think the mag drill can give the results you want. Best would be to take the part to a machine shop to be done on a milling machine to get best results. Lesser quality, but possibly OK results might be had by setting up angle iron guide and using a cutoff wheel type grinder with a thicker wheel, slow and tedious. Might want to reveal your top secret location, maybe someone local can help.
Jim

 

[larry_g]

If you need a mill to come to you then one of the tools t hat can do it is a Versa-mill . However what prevents you from bringing your work to the mill? Got any pictures? I can say I would not attempt to do the job with a mag base drill. I would be more inclined to use a router type tool where you could set up a fence and slowly grind away the excess material.

lg
no neat sig line

 

[E.Marquez]

MAG drill is not likely to produce the quality results your looking for. Just not ridged enough, nor designed for the side loads required of a milling operation in that kind of steel.

If the part is portable, best bet is to take it to a piece meal machine shop.. Cost should be reasonable as that is a very simple set up and milling operation.
If the task requires you to do it on site….. you’re going to have to have somewhat lesser expectations on the outcome I think,, expecting function over looks.
Cut off wheel for general material removal and a 4 ½ angle grinder for clean up can produce the increased slot size… but it’ll not look like a cleanly machined part when done that’s for sure.

 

[RECox286]

Not to be blunt, but take your project to a good machine shop, or wind up with

whatever you wind up with.

Uncle Bob

 

[geologist]

You're taking 1/8" off of each side of the slot. Is a file out of the question?

 

[king nero]

You're taking 1/8" off of each side of the slot. Is a file out of the question?

that noone has mentioned this before... a file used to be my favourite tool. simple yet effective. done many square drives with a half inch drill and a file.

 

[OccupantRJ]

A woodworking router with a mounted stone as is used in a die grinder could do the job by running against a fence. Just be sure the stone is rated for the speed of the router. I used a router to machine the cylinder openings larger on an aluminum motorcycle engine for an overbore job by using a speed control, and used a cylindrical burr bit. A jigsaw could also be used to rough cut the slot, then dress it clean with the router setup.

 

[sberry]

cut off wheel or sawzall. Maybe a simple 4 1.2 grinder. Where is the picture?

 

[bad_idea]

I don't have a camera and bringing the piece to a machine shop is out of the question due to the size of the piece.

A router sounds interesting. The material is 1/2" thick though.

 

[rsanter]

Die grinder and a file

O
If you use the mag drill you could nip away at it then finish with a file

Bob

 

[bad_idea]

I am thinking a hole saw at each end of the slot to make a larger radius-ed end and then use a piece of angle iron as a guide for a 4 1/2" cutting wheel to connect the two holes.

 

[srmofo]

Drill some holes along the slot, and clean up the high spots with a file. I've done this on thinner material

 

[bad_idea]

What kind of file are you guys using on 1/2" plate? Is there a file more aggressive than a ******* cut? I use a large ******* cut for knocking burrs off of parts and it doesn't remove THAT much material. I can't imagine using one for this task, sounds like a sore arm and lots of time to me. What am I missing?

 

[metaleltr]

What kind of file are you guys using on 1/2" plate? Is there a file more aggressive than a ******* cut? I use a large ******* cut for knocking burrs off of parts and it doesn't remove THAT much material. I can't imagine using one for this task, sounds like a sore arm and lots of time to me. What am I missing?

http://www.amazon.com/dp/B005VR56SI/?tag=atomicindus08-20

A vixen cut file would work faster,but it would still take forever.

 

[bad_idea]

Thanks metaleltr for the file info.

I used a hole saw at each end of the slot and connected the two with a cutting wheel on a 4 1/2" grinder running along a piece of flat bar as a half assed fence. Then cleaned it up w/ a burr bit and then a file. Took a while, but it looks decent. It doesn't stand out as hacked, but if you are looking for it, you will see it. Thanks for the input everyone.