Preparing Aluminum Plate - Router Forums
 
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post #1 of 6 (permalink) Old 12-18-2007, 04:05 PM Thread Starter
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Default Preparing Aluminum Plate

I have some nice aluminum plate and I want to make my own router mounting plate. I have worked with some of this stuff already and know it's rigid enough, but still quite workable for me. Questions are (1) what should I use to drill the hole for the bit? (2) how big should I drill the hole? and (3) Does anyone have any suggestions on how to make inserts for differrent size bits?
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post #2 of 6 (permalink) Old 12-18-2007, 06:40 PM
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Hi Rocky

You may not want to use the Alum. plate you have, and this is why..

Alum. is dirty,,,that's to say it will put black marks on your projects that are hard to get out/off,,,

You may want to pickup some plastic,poly,think cutting board they are cheap and clean and you can rework them just like wood...I got one from Kmart last week for 16.oo bucks and it was 1/2" x 15" x 20"

BUT if you still want to use the ALum. you have repost and I will try and give you a hand...

But do take a hard look at the item below..

http://www.harborfreight.com/cpi/cta...emnumber=94331

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post #3 of 6 (permalink) Old 12-18-2007, 07:24 PM
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Just a quickie question: how about anodizing the aluminum, after all the driilling and shaping has been done?

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post #4 of 6 (permalink) Old 12-19-2007, 08:56 AM Thread Starter
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Thanks for the responses.

The plate is already coated. It is either anodized or powder coated. The plate was originally intended to be a blank cover plate for an electronic equipment rack. Most of these are too thin, but I have one that is nice and thick, very rigid, perfect for hanging a router. I just need to know what kind of bit to use to drill the main hole, and the best size. I plan to fabricate a coller to go below the hole with an edge sticking out (with 2 or 3 screw holes) so I can make various inserts with smaller holes and mount them to the plate.

Will a standard hole saw cut aluminum? I know that regular twist drills work well, just don't know about the hole saw.
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post #5 of 6 (permalink) Old 12-19-2007, 10:25 AM
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Yes, hole saws(and router bits) will cut aluminum. A couple decisions need to be made before you start cutting. Are you going to provide mounting for guide bushings and if so will they be PC style or the larger, less common but more versitile Router Workshop style? Since you only have one of these plates will you cut it to match one of the commonly available plate sizes so a larger or smaller router can be used in the same table? As far as mounting a collar under the table to support inserts, it sounds like a bad idea. Odds are it will interfere with either the mounting of your router or the size of bits you can use in it. Instead of re-engineering the wheel if I was going to make an aluminum mounting plate I would cut the center to accept the Rousseau inserts and starting pin.(about $10) Of course for $20 you can buy the HF mounting plate which is a copy of the Rousseau and save your self a lot of time and work. I do not want to discourage you from building your own plate but I wonder if you couldn't find a better use for that nice piece of aluminum?

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post #6 of 6 (permalink) Old 12-19-2007, 10:28 AM
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Hi John

Most hole saws will cut Alum.some are made to cut mild steel,the same thing is true for drill bits..

The main hole,,,You only want to do this one time, so it should be a 3 3/4" hole to take on the big panel bits,,then you will run into a error because a 3 3/4" / 4" hole saw is not cheap and then you need a lip to hold the insert ring...on top of that, you can use a fly cutter in the drill press that will do a good job..and put in the main hole and the lip.
http://www.grizzly.com/catalog/2007/Main/614

But if you say I don't want to go that big at this time, that's fine, just chuck up the 2 1/2" hole saw and start the hole in the drill press but only drill 1/2 way into the plate,remove the plate from the drill press and use the 1/4" hole to line up the router on the Alum. plate,,a 1/4" dowel pin works great for this job,chuck up the pin and use router to line it up,draw around the base plate and remove the sub base plate (the black one the norm) now mark the holes to mount the router to the new plate,then drill them out and counter sink them once you done that test the fit,once it fits then back to the drill press and drill out the 2 1/2" hole,,,,now for the insert rings, start with one that is 3" OD and 2 1/4" ID once you have it made 3M glue/super glue, it to the base plate this will give you the lip to hold the rings...then make the other rings the same way but they will all be 2 1/2" OD to fit on the plate...you will need to use the same stock for the rings they need to sit FLAT in the hole..


Hope this helps

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