Nibbling tool for building pedals

[tsutt]

you can use a shot of wd 40 for lube if your getting alum stuck on the cutter. Just use some common sense and be sure handed been doing it for years. have never had a problem. and yes it is messy. i recommend long sleeves and gloves.

[cbass]

And eye protection

[xtian]

Also, don't wear fleece. Metal shavings get stuck in the fabric. Ask me how I know.

[rp]

Also, don't wear fleece. Metal shavings get stuck in the fabric. Ask me how I know.

hahah I did custom av and I was on construction sites all day, company I worked for wanted to get us swag w/ their logo and was going to get us fleece jackets. I said save your dough, I'm not going around wearing a Swiffer all day.

I was curious as normal speed on a router seems way fast for Al, enough to melt it. As I need a new 220V router best get variable speed. The metal shaving mess might prevent me from trying this but this seems like the best way to get a nice clean cutout for a laydown trannie.

How do you all make templates, then? cbass, I take it you cut your templates out of thin plywood or plexi?

[tsutt]

RP, with carbide there really is no issue. Although the alloys they make chassis out of are a bit gummy thats why i would use the wd 40, you can use kerosene also just a bit stinky. You can use whatever you like for a template. the general idea here is that you use one of the trimmer bit that has a bearing on it that rides on your template. if not use one that has a shank diameter the same as the cutter run the solid shank on the template. FYI some of the machining centers have spindle speeds up to 40k or more.

[rp]

I'm comfortable around power tools, just metal is all brand new to me. If I can figure out the shavings litter problem I will give it a try. First time I'll don Carhartt armor head to toe, goggles and gloves till I'm convinced it all won't explode when the bit hit's the Al.

[tsutt]

I saw alum plate up to 2 " thick on a table saw noisy. I have used router to cut 1/2 radius on plate just take multiple passes.

[cbass]

I make my templates out of hardboard.I use a 1/4" bit with a 1/4" shank.I'll try to take a pic if I can find it.Lately I've just been Hardwiring the power cord

Drill out as much aluminum as you can first.Of course make sure the chassis is clamped to something solid

[Tillydog]

...If I can figure out the shavings litter problem I will give it a try.

More a glitter problem than a litter problem

+1 on the fleece. If you've got a teflon suit, wear it!

FWIW I use a 6mm bit with a 10mm guide bush on the router (roughly 1/4" & 3/8"). That means making oversized templates (thin, cheap plywood or hardboard), but it's no problem. I have a vacum extractor attachment on the router, but clamping the vacuum cleaner nozzle in just the right place works best for me.