Routing aluminum

[Victor Robinson]

I'm working on a jig and I want to be able to rout a very shallow (1/64"D x 1/2"W) dado (technically a rabbet) in an aluminum extrusion (to provide space for a lexan Incra scale).

It would be a very very shallow cut performed on the router table with fence. The extrusion is flat, wide, and heavy so stability on the table should not be an issue. I could do the width of the rabbet incrementally for added caution. Is it possible to do this with a standard straight bit, or is a spiral much preferred? Any other considerations?

[Mel Fulks]

Squirting some denatured alcohol will keep it cool and make it cut without gummyness

[Frank Pratt]

Fire hazard. Alcohol dripping down onto the router motor.


Squirting some denatured alcohol will keep it cool and make it cut without gummyness

[Mel Fulks]

Thanks Frank,I missed the router TABLE thing. Still a good idea with motor up operation.

[Martin Wasner]

I'd pay a machinist $10.

[David T gray]

just do it set up feather boards i wouldn't even worry.

[Nick Decker]

Pat Warner, where are you?

[Ben Rivel]

Pat Warner, where are you?Not doing well as I understand it.

"Pat replied to my email but it doesn't sound good. Might want to add him to your prayers....
Pat's reply: "Bad news, I'm ill & will not make any more 1400 plates unless I go into remission or these symptoms subside, PW"

[Jerome Stanek]

You could do it with a 1/2 inch straight bit a little WD40 would help but that shallow is not any problem

[Victor Robinson]

Thanks to everyone except Mel. Burned down my house. (kidding on both counts of course) :D

Martin - I'm almost positive any machine shop in my neck of the woods would easily charge me $75+ for this. One time I had a shop press on a bearing onto a cutterhead - took them 2 minutes and cost me $20.

Pat's in my thoughts.

[Jerome Stanek]

You could also do this on a table saw

[Nick Decker]

Not doing well as I understand it.

"Pat replied to my email but it doesn't sound good. Might want to add him to your prayers....
Pat's reply: "Bad news, I'm ill & will not make any more 1400 plates unless I go into remission or these symptoms subside, PW"

Didn't know that, and sorry to hear it.

[Victor Robinson]

You could also do this on a table saw

Very true...I've always been a little gunshy about aluminum on my Sawstop figuring the aluminum shavings in the saw guts could set off the brake at a later point, even though in theory that shouldn't be the case.