Getting ready for a 4x4 build

[CaptRR]

Hello all,

Earlier this year I build one of the buildyourcnc book machines. I always took it at a learning experience, which it was. Also in the humid Virginia weather I have found that the book machine is not aging very well. The other day I was looking at ways to improve it and came to the conclusion that it would be better to build a new one from scratch.

The design I want to use is a joes 4x4. It seems the be the right size, and having the frame made of metal seems like a good idea in retrospect.

However I have some questions.

The big one is, how to cut the 8020 aluminum. As of this point almost everything I have is wood working tools. Can I get these peaces precut to the correct length? Or should I buy a new power tool for my small shop to cut these pieces.?

Finally, I am thinking of going with a rack an pinion drive. I have read that I will lose some accuracy. But is this really that big of a deal? I will be mostly cutting wood, with the occasional aluminum sheet. Right now my current book build is using a hardware store screw, so I imagine the rack and pinion will at least be better than what I am using now.

Thanks

[uspl]

Hi

If you have a drop saw or compound mitre saw that will handle the material size, then no problem. Get an 80T or 100T blade from your supplier to suit, make sure you tell them it is for cutting aluminium. Also get some cutting / lube compound, comes in a wax stick like a giant candle.

My blade is an Irwin that cost me $90AUD and cuts 8020 like butter in my 8" drop saw. Make SURE you clamp the work well and use a smooth clean cut, not stopping or backing off halfway. The swarf is like fine snow so I put a stocking over the motor housing to keep it out, wear eye and breathing protections as well, if you think sawdust is bad for your lungs try fine aluminium.

I am also starting a new 8020 build, see my thread at Proposed T-Slot 8020 Build in Oz

Good luck

[ger21]

You can also cut the aluminum on a table saw, ideally with a sliding cutoff sled.
As mentioned above, you want a non ferrous blade, but a high tooth triple chip blade (for laminates) will work well too.

[uspl]

Yes you could but the swarf problem is even worse on a table saw. You will need a very good extraction setup if you don't want to kill your saw real fast.

[ger21]

I've seen aluminum cut for years on table saws with marginal dust collection, and no problems.

[CNC-Joe]

Another option is to purchase an inexpensive metal cutting bandsaw.
I purchased mine for $150 on sale, and use it for everything.

The 8020 that I purchased for my 4x4 Hybrid build (still haven't gotten around to building it...) was cut to approximate length by the supplier (( 8020 Salvage). The 4x4 Hybrid is very forgiving - you can have the 8020 parts longer than necessary -and it will be just fine.

[CaptRR]

I live in constant fear of my table saw since i had a kickback a few years back, so I don't think I will be trying to cut metal on that death trap. The miter saw is an idea, but the one I have is not a compound miter saw, so I am not sure that would work either.

Looks like I am going to have to find bandsaw, though I hate to buy something I will most likely only use one time.

[ger21]

You don't need a compound miter saw, just a regular one will do. A compound miter saw just cuts 2 angles at once, which you shouldn't need to do.
I have a 12" dewalt non compound miter saw, and have cut plenty of aluminum with it. But I still prefer the table saw for accuracy.

[RossMosh]

I have to ask, why not spend the couple of dollars and get the extrusion cut to length?

[CaptRR]

I have to ask, why not spend the couple of dollars and get the extrusion cut to length?

Will the companies that sell the extrusion cut it to the exact length I need? I was under the impression they only sell lengths that are close, not exact.

[RossMosh]

Will the companies that sell the extrusion cut it to the exact length I need? I was under the impression they only sell lengths that are close, not exact.

I'm not sure if 8020 will cut garage sale items on eBay, but if you order "new" extrusion from 8020 or a distributor they will absolutely cut to length. Some places charge a good bit of money for the cuts ($4-5) but in the end if you only need 3 cuts, it's worth the $15. Automations4less.com sells 8020 and does not charge for the cut. The biggest benefit of them cutting is their accuracy. I believe 8020 requires any distributor to purchase a specific saw for cutting their product. It allows for ultra precise cutting.

[CaptRR]

I'm not sure if 8020 will cut garage sale items on eBay, but if you order "new" extrusion from 8020 or a distributor they will absolutely cut to length. Some places charge a good bit of money for the cuts ($4-5) but in the end if you only need 3 cuts, it's worth the $15. Automations4less.com sells 8020 and does not charge for the cut. The biggest benefit of them cutting is their accuracy. I believe 8020 requires any distributor to purchase a specific saw for cutting their product. It allows for ultra precise cutting.

I don't mind buying it new. I figure, when all is said and done, its going to be expensive anyway, so why not buy from someone trustworthy, and if they can cut it for me, all the better.