Sheet Aluminium Cut Edge?

[GalaticDan]

Hi,

I've purchased some Aluminium sheet 1/2" think from a local dealer, problem is it's to large for my hobby mill to edge finish. The sheet is over 1/2 a metre square and the supplier can only bandsaw cut to my required dimensions -0 +2mm. Any suggestions about how I can get a better edge on this sheet which is to be the base of my next project. I would have prefered a nice machined edge. I've large linear rails and did consider making a JIG up with my porter cable router; do you think this will work? If so what router bits as my closest store only stock the standard kitchen stuff for laminate or wood work top routing.

Dan

[ger21]

Just clamp a straight edge to guide your router, and take a VERY light cut, at full depth with the router. Use a spiral carbide bit for best results. A straight carbide tipped bit will work, but a spiral will cut smoother and easier.

[Bruggles]

Try a 1/4 inch carbide endmill, they seem to have the best results, if you go over it at a slow rpm (slow for a router 14,000ish) use an oil of some sort, A9 seems to work the best, but WD-40 will work as well, you just need to apply the wd40 more often, because it is not as thick. The reason for the 1/4 endmill vs. a larger size cutter, is because if it grabs it is a lot less severe when holding the router by hand (may not be an issue if you are taking very light cuts around 1/16 or smaller). For the finish cut, try climb milling at your routers highest rpm, after you have already gone over it in the conventional way a couple of times without moving the straight edge. You can get a mirror finish this way, well that depends on how concentric the cutter is in your router as well.

[ViperTX]

Yes, you can use a router (use a bit with a bearing and have the router mounted on your router table) or get a non-ferrous blade for your table saw and take that route.