Best solution for surfacing 4x8 MDF?

[ironspider]

Greetings all, I am very new to the "hobby" of CNC and I am approaching completion of my CNCRouterParts 48x96 build. I want to surface the MDF spoilboard but I'd like some advice on the best way to do it with a ER16 Chinese Air-Cooled (1.5kW) spindle? More precisely, what type of bit should I use and what are the ballpark settings (feed, speed, depth, stepover) I might want to use?

It seems like most of the surfacing bits I have come across are 1/2" or larger shank and I think the ER16 max size is 3/8? I read a couple of threads about using a "fly-cutter" for surfacing but I can't seem to find any at 3/8" (and I'm not even sure if that's the best way!).

So I'd love for anyone to be able to give me some guidance, I thought building this thing would be the hardest part but now I'm in a different arena of feeling overwhelmed

Thanks!

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[ger21]

You're really going to want a spindle with a 1/2" capacity. I doubt you'll find anything with a 3/8" shank that's larger than 3/8" diameter. Your best option might be to use the largest straight 2 flute router bit you can find with a 1/4" shank.

With a 1/2" shank, I'd recommend these, but you're going to have a very difficult time with that small collet.
Mini Insert Spoilboard Surfacing & Rabbeting Router Bit with Scorer 2 + 2 Design -Toolstoday.com- Industrial Quality

Spoilboard Surfacing Insert Cutter Router Bit - Toolstoday.com - Industrial Quality Insert Bits

[ironspider]

Thanks Gerry, so is there any way to make my er16 capable of handling a 1/2" shank? I did a quick search and saw in another thread that Soigeneres used to carry a "Solid Tool Holder" (which I imagine would have a 3/8" shank or something but an opening of its own to accommodate 1/2" shank?) but the link is dead.

If I can't make this thing hold a 1/2" shank do you have a link to an example 1/4" shank (or 3/8" shank) bit that would be suitable for this procedure? Although I'm sure it would take a ton of time to complete the surfacing?

[Bob La Londe]

There is a tool holder that threads onto an ER16 spindle in place of the nut that will hold a 1/2" shank tool. I have not used it.
http://www.a2zcorp.us/store/ProductDetailNP.asp?Cguid={DAF06CA8-976A-4230-B7F1-A0B554D84874}&ProductID=4323&Category=EndMillHolde r:ER16

Here is a fly cutter with a 3/8 shank. I have not used this either.
http://www.a2zcorp.us/store/ProductDetailNP.asp?Cguid={DAF06CA8-976A-4230-B7F1-A0B554D84874}&ProductID=5647

[ger21]

Do NOT use one of those flycutters in a router. They are not designed for the high rpm's and would be extremely dangerous.

You can get a 1" diamter bit with a 1/4" shank here:
Straight Bits - Straight Bits / Plunge Cutting Bits

[Bob La Londe]

Ger is right. A flycutter at router speeds is very dangerous. I was just pointing out that they are available in 3/8 shaft. Also, I believe you might have to buy a premium name, but I think ER16 collets are available upto 7/16.