Thermwood Router Table Repair

[SheldonB]

Looking for suggestions on what type of tools to use for drill & milling the hard organic composite table on our router (press oats or??).
Has anyone had any success in drill or milling these types of tables?
Do you use HSS, cobalt or carbide drills or mills?
Any special flute design? High helix?
Can you use some sort of lubricant "WD-40" without damaging/weaking the table material.

Any & all info is appreciated.

[Mussel Kar]

Are you talking about thick phenolic? If so then carbide is the best answer. You are looking for a heavy chipload and a low rpm to get better tool life(compared to wood). Low helix finishers work best for the final cut, if needed.

[Geof]

Use good masks while doing this, phenolic dust can be very irritating.

[jaushaug]

I've machined 60 or 70 black phenolic tables on routers. I faced with a 2-1/2" 45deg 5-insert indexable shell mill - 0.020" rough & 0.005" finish depth, 12000 RPM @ 400-500 IPM. Grooved with brazed carbide bull-nose spade-type endmill - @.150 deep, 12000 RPM @ 200-300 IPM. HSS drills work well at heavy chip loads and higher RPM than used in alum - ex. 1/2 drill @ 4000 RPM & 25 IPM with .200 peck. This was with 11HP spindle. With 5HP all the same except 1-1/2" shellmill because of shank dia limitation and drill slower (and only up to @3/8). Definitely wear a mask, I get sinus infection every time I don't.