Routing 6061 Aluminum HELP! - Router Forums
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post #1 of 16 (permalink) Old 01-06-2016, 12:19 PM Thread Starter
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Question Routing 6061 Aluminum HELP!

Hey guys and gals,
I want to make a template, or jig, out of aluminum, essentialy a stair routing template. I have made them out of wood before, many times, but I want to try something more durable. I'd like to try my hand at routing an aluminum template out of 1/2" 6061 stock and am looking for ANY advice I can get....

Thanks!

Jack


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post #2 of 16 (permalink) Old 01-06-2016, 12:27 PM
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First off, it will make a mess.LOL I have never router a piece that thick, you will probably have to do it in small increments of depth.
You will probably be using a template and a bushing and hand held router. years ago when I worked in a machine shop, they did it all the time making aircraft parts and had to use a liquid coolant on the bit and a spiral bit, can't remember if it is up or down spiral.
Someone will be along with all the information soon.
Also the type/grade of material matters a lot,some machines better than others.

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post #3 of 16 (permalink) Old 01-06-2016, 12:50 PM
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my best advice is buy one already made.

Or go to a machine shop, because youre bound to screw up once, and unless you have free access to the ali, your money and time spent will make it a very expensive jig.
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post #4 of 16 (permalink) Old 01-06-2016, 02:07 PM
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I've routed aluminum but fairly thin . You need to cut out the majority of the material as close as you can to the size needed , then have a router bit guided by an mdf template to take off the rest . Have someone spraying wd40 as the bits routing out the aluminum

I don’t always insulate , but when I do .
Ok ,I never insulate
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post #5 of 16 (permalink) Old 01-06-2016, 02:52 PM Thread Starter
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Originally Posted by sunnybob View Post
my best advice is buy one already made.

Or go to a machine shop, because youre bound to screw up once, and unless you have free access to the ali, your money and time spent will make it a very expensive jig.
No free access here, but nothing ventured, nothing gained. Yes, I will be using a hand held router, a Porter Cable 7518, single speed so it might be the 19, I can't remember. Part of it is to save money, buying one is crazy expensive, and part of it is simply learning to do it myself, and actually doing it myself. Make one, figure out how it goes, that opens the door for next time. I don't want to be afraid to try, hell, I don't want to be afraid of anything. Fear is my enemy. Wisdom is my friend.
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Jack


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post #6 of 16 (permalink) Old 01-06-2016, 03:32 PM
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...for cutting slots in closed stringer...? or to set step and riser...?

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post #7 of 16 (permalink) Old 01-06-2016, 03:47 PM
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...for cutting slots in closed stringer...? or to set step and riser...?
That is a good question, and difference in making the template. I just ass-ssumed it was closed stringer. Another question is how long will this template be,for how many treads and risers? Will it be adjustable for different runs and rise? Hmmmm so many variables........

Maybe do a mock up in Baltic Birch plywood?

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post #8 of 16 (permalink) Old 01-06-2016, 04:11 PM Thread Starter
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It's for housed stringers, so it will route out the run with nosing, and the riser. It will also include the space needed for stair shims. No baltic birch necessary, I have made these before but always out of plywood. There is no rise/run, or pitch, it's simply one tread and riser. I clamp it down, route and then move it to the next step and repeat. The rise/run is set by the angle that the template is clamped to. The real question remains, practical advice on routing aluminum.

Jack


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post #9 of 16 (permalink) Old 01-06-2016, 04:25 PM
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Quote:
Originally Posted by Jack Wilson View Post
It's for housed stringers, so it will route out the run with nosing, and the riser. It will also include the space needed for stair shims. No baltic birch necessary, I have made these before but always out of plywood. There is no rise/run, or pitch, it's simply one tread and riser. I clamp it down, route and then move it to the next step and repeat. The rise/run is set by the angle that the template is clamped to. The real question remains, practical advice on routing aluminum.
Yup...got it...mine is plywood also...aluminum sounds like a great idea but thinking you might need liquid coolant and slower speed...
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post #10 of 16 (permalink) Old 01-06-2016, 07:24 PM
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Yup...got it...mine is plywood also...aluminum sounds like a great idea but thinking you might need liquid coolant and slower speed...
The second best car audio installer in North America (The FishMan) routes aluminum all the time . Exactly as I described it

I don’t always insulate , but when I do .
Ok ,I never insulate
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