Router for thin aluminum

[Iguanadon]

Hey guys,

I've been reading up for a while about CNC routers and the such and I decided that I would like to build one.
At first I was looking into converting the Harbor Freight micro mill into a CNC mill, but at the time I couldn't find any plans that were in depth enough for me to feel comfortable doing it. Right now after reading up on routers and other CNC related things I'm sure I'd be able to do it, but a CNC router seems more versatile because of its increased table sizes.

I like the looks of the solsylva plans but after sending an email to David about some things I would like to use it for I'm a bit hesitant about pulling the trigger on the $40 plans.
One of the major things I would like to be able to do with the router is create my own projection gobos. I'd be cutting very thin aluminum (the thinnest I could find so far is 0.025" from onlinemetals.com, I can use 0.005", I just don't know where to find it) creating designs such as this link
The circle is around 1.5-2" and white is what would be cut out of the aluminum.

In addition I would like to use the router for PCB milling and drilling and cutting / engraving wood.

I would like to keep the total cost under $600 (sans computer), I have a Makita laminate trimmer that I would use for the spindle and I have a decent sized collection of tools that I can use for building it. Do you guys think that the solsylva plans will be able to cut thin aluminum cleanly? How about doing PCBs?

Thanks in advanced

[Oldmanandhistoy]

Personally I would build the smallest and tightest machine I could to cut your gobos and PCB’s like this one 3rd Generation Router Build and if you want a larger machine build another for the larger jobs.

John

[Oldmanandhistoy]

One other thing if you do consider the machine which I linked to have a look at this thread Seeking design feedback before I start and take a close look at his Z axis using hex bar. That is similar to how I would do the Z for my suggested machine; much simpler than the original one and just as rigid imo.

Good luck,

John

[ger21]

Cutting thin aluminum can be very difficult, especially with a high speed spindle and no coolant.

[Oldmanandhistoy]

Originally Posted by ger21 Cutting thin aluminum can be very difficult, especially with a high speed spindle and no coolant.

Make the suggested machine out of a rigid plastic in place of the MDF; a good bond on the joints and you could use a flood coolant.

John