80/20 Cutting Slot for Clamps

[Bugsysiegals]

I'm building a MFT cart like the one in the link below using 80/20.  The Festool clamps fit in the track amazingly but only slide in if the end is open.  As seen in the images of the cart below, I'll have several segments which do not have the open ends and can only think to grind some material away so the clamps can slide into the track as also seen in the link below.

The question, how do I remove aluminum material in a way which looks decent and isn't jagged and sharp afterwards?  I was thinking perhaps there's some sort of bit I can chuck in my drill press, set up a fence, align the extrusion so the bit is centered, and slide the extrusion down the fence to get a nice straight cut.  Is there such a bit which would cut in this way and leave a nice finish or is there a better way to achieve this?

MFT Cart

 

[Dick Mahany]

Aluminum can be milled with carbide bits in a router.  Possibly construct a jig such as the type used to mill recesses for door hinges and secure to the extrusion.

 

[Bugsysiegals]

Would I use something like this??  If anybody has a better recommendation for a bit, please advise.
https://www.toolstoday.com/solid-ca...zirconium-nitride-zrn-coated-router-bits.html

 

[Dick Mahany]

Would I use something like this??  If anybody has a better recommendation for a bit, please advise.
https://www.toolstoday.com/solid-ca...zirconium-nitride-zrn-coated-router-bits.html

You could call the folks at Whiteside Machinery about your application.  They are very helpful and their router bits are excellent.  I'm sure they could advise for the best option.

 

[Michael Kellough]

I’d use the track saw on the MFT. I’m comfortable with that settup but I have not routed aluminum.

 

[rst]

I mill lock cutouts in aluminum doors with aluminum router bits that I buy from Toolstoday.  I use WD-40 for lube, works great although it makes a horrendous noise.  Take light cuts.  I used my MFS jig with 3" angles attached to the jig and clamped to the doors.