Never milled but have a project

[mikesativa]

I'm not planning on buying or building a CNC. I need more space before I can get one.

I was giving a piece of 6.35 mm sheet T6 aluminium to work with so I want to build a new extended chassis for my RC Savage. Trying to keep the front tires on the ground. I will also be moving the motor,transmission, fuel tank, and radio gear for a lower center of gravity. I've never built one but I think I'll be ok once I get started.

My garage: I have all hand tools,air tools, ryobi router(1 1/2 HP), dremel, drill press, table sander. I'm a mechanic by trade. I thought it would be a good idea to stop in here and see if you guys could recommend some bits that will work for this little project.

My questions:

1. Which tool would be better for making the inside cutouts and what bits would I use? Dremel or Router.
2. would this bit work with my router? Ryobi 1 1/2 HP single speed(25,000 RPM)
http://wttool.com/p/0957-0005


Here is a factory set


Mine will be twice as thick so I want to make more cut outs and get a one of a kind look. And reduce weight. I hope I have given enough information to get some sound advice. Thanks in advance for you help.

[Ken_Shea]

In looking at your similar part and not having a mill, a good quality sabre saw and blade then finishing up with a file might be your best bet.

Perhaps I am reading your post wrong, but you do not want to be using a hand held router on aluminum.

Ken

[WhiteTiger]

I'd suggest a combo of your drill press and dremel. Layout your cuts and drilll a series of holes inside the cut line, then "connect the dots" with the dremel and a cutoff disc. From there it's just a matter of working out to the scribe line with dremel and files.


Tiger

[mikesativa]

Originally Posted by Ken_Shea In looking at your similar part and not having a mill, a good quality sabre saw and blade then finishing up with a file might be your best bet. Perhaps I am reading your post wrong, but you do not want to be using a hand held router on aluminum. Ken

I wasn't gonna reveal how i was gonna use it till I had a suggestion or two. What do you think of this. I was thinking o making something like this for the router. He is using the alum as a guide to cutout a chassis from carbon fiber
http://www.mkeeler.com/savage_twin/T...ngstation2.jpg

[Ken_Shea]

That looks like a workable idea for sanding but no cutters. I have never cut or sanded any carbon fiber composite but from I have read it cuts and sands easily.

[WhiteTiger]

Handheld router or handheld workpiece, it amounts to the same thing. If you attempt the interior cuts with the router I hope you have lots of extra 1/4" aluminum and good insurance on your fingers


Tiger

[mikesativa]

Originally Posted by WhiteTiger Handheld router or handheld workpiece, it amounts to the same thing. If you attempt the interior cuts with the router I hope you have lots of extra 1/4" aluminum and good insurance on your fingers Tiger

So it could grab the piece? It must take a bit of force to get it to cut then. Is this a good bit to use at 25000 RPM? How about a carbide bit instead?

[WhiteTiger]

If you're going to hold the workpiece by hand, no toothed bit is a good bit, imo.

No one is that strong or has that precise muscle control. The bit is going to skip, slide, bounce and erratically bite... sooner or later it will get hot enough to clog with chips or it will hit a point that it bounces back into the work trying to take too big a bite, and the workpiece will be ripped out of your hands. I've seen more than one guy with splinted fingers from doing such things.

If you absolutely insist on using the router for some strange reason, look at double cut rotary burs such as are used with die grinders. What you want to avoid at all costs are cutters like the one you posted the pic of, that have full length continuous cutting teeth. If you're going to use a metal bit and not abrasives, you want the teeth on the bit to look like these. The teeth are cut in such a way that the tool is essentially a very coarse fixed grain grinding wheel.


Tiger

[bennett71]

Do you have any laser or water jet shops in your area?

[mikesativa]

Yes, I think there are shops that could cut this for me, but then I might as well just buy some and save a few bucks. The best ones made are $90. I'm trying to get this done for free with what I have on hand.

That's good cause I do have some of those bits for my die grinder so I'm all set.

Plan as of now.

Cut main outline with table saw.
drill staring holes for the cut outs.
use a jigsaw to remove most of the material.
die grinder and dremel to finish the inside cuts.
sand the inside like this:

Progress. I have an idea of how to start. Now I need to make my drawing template. I'm going to cut an old chassis and stretch it one inch/25.4 mm. bolt it to my work piece and leave it attached till it ready to be polished. Sound ok so far? Thanks for all your input on this project. I feel I have what I need to complete the task and can get started.