Cutting aluminum part, feedback?

[mcooley]

Curious if any of you have thoughts about either using my 1400 router or Carvex to cut this part out of aluminum?

It would 1/4 or 6mm thickness 6061 plate of aluminum.

The shape and angles are the most critical. The placement of the holes on the tabs and the "cut-out" shape between them is not necessary. The hole on the drop-out portion is critical.

It may be possible for me to make a cut file and get this milled but trying to think of alternatives. Unfortunately, I do not have a band saw currently at my disposal.

Thanks!

 

[Locks14]

That is (IMHO) a 100% candidate to be outsourced to a CNC shop and see the $$$ cost as an investment in saving you countless hours and probably frustrating mistakes.

 

[jbasen]

That is (IMHO) a 100% candidate to be outsourced to a CNC shop and see the $$$ cost as an investment in saving you countless hours and probably frustrating mistakes.

Or, an excuse to "invest" in a desktop CNC machine and learn to do it yourself.  Unfortunately, Festool doesn't make one so it won't be green but there are tons of quality CNC's on the market and the prices keep coming down.  There was a recent thread in just the last few days on a very nice looking machine for only $1000. 

There are a lot of videos on YouTube with information on using a home CNC to cut aluminum.  I haven't tried it myself but the tricky part seems to be that the router spindle speed is much faster than you would really want for aluminum.  I'm sure there are people on the FOG that can provide you with additional info.  I just have a home CNC that uses a Dewalt 611 router.

 

[GarryMartin]

I'm with [member=49749]Locks14[/member] - having downloaded the PDF and read your description of what you are trying to do, I don't believe a router or a jigsaw are the correct tools for the job. Definitely one for the outsource list...

 

[Kev]

You could spend a lot of time with a pedestal drill and a file!

 

[rvieceli]

CNC shop... I'm betting the cost won't be as much as you think. It will save you hours of frustration and the cost of ruined materials and possibly tools.

 

[Cheese]

Curious if any of you have thoughts about either using my 1400 router or Carvex to cut this part out of aluminum?

It would 1/4 or 6mm thickness 6061 plate of aluminum.

This can be accomplished with the 1400 & Carvex as long as you have 3 things:
1. A pallet load of 6061 sheet stock because you'll probably burn through most of it before you're happy with the results.
2. A lot of time...and time measured not in hours or days but more likely in weeks or months.
3. A full head of hair because you will certainly be bald when the finished product is completed.

If you can't provide all 3 ingredients...then find a machine shop with CNC capabilities. The machine shop will provide you with a finished part at less cost than the pallet load of sheet stock. [eek]

 

[AlexThePalex]

You can cut aluminium just fine with a router and a proper bit.

But the shape you want to make here is pretty complicated, not an easy task with a hand held router.

 

[Holmz]

You can buy those bicycle parts from a hundred sources in a few materials.
(Assuming a bicycle).

 

[mwildt]

I'd try talking with a CNC shop. I've seen Tormachs being used by nyccnc. Check what they can do for you. No affiliation but he comes across as a genuine guy. Check his YouTube channel.

 

[Scorpion]

Interesting bracket, what's it for?  Curious.

The part would need to be modified in a couple spots (inner corners can't be square) if it were to be milled.  Otherwise you're looking at water jet, laser, or CNC plasma.

 

[Kev]

You can buy those bicycle parts from a hundred sources in a few materials.
(Assuming a bicycle).

I thought same .. but it is a bit peculiar

[member=40772]Holmz[/member]

 

[alexander]

If you are willing to want to learn CNC, but don't want to invest in a machine. You could find a makerspace where you will be able to learn the process and cut your part for a reasonable price.

I teach new people coming to our local makerspace how to use CNC, lasercutter and so on. So plan a few evenings to learn and you will have your part and learned how to use a CNC, which is a handy thing for some other projects.

Alex

 

[mcooley]

Thanks All for the great comments!

I am in the midst of getting quotes and waiting to hear back. I also have a friend who might be able to do it with a mill.

As for the design, well, it is a bicycle dropout but because the tabs need to be rather wide (and a vertical style hanger and not a track style one) the part is not that easy to come by. I either have it made here or pay a heavy price bringing it in from the UK. I prefer knowing I can get it again, here, for future projects.

The project can be seen below at this link. The second more refined frame should be done by the end of the month. Interesting process and kind of a mashup of a couple different approaches one being Craig Calfee well known for his bamboo bicycle frames.

http://bamboo-bike-build.blogspot.com/

 

[Holmz]

what is a havy sipping price in US$?

 

[Cheese]

Rather interesting project...what's the allure of using bamboo for a frame?

 

[KBJ]

shoooot. I have a milling machine and that would be a pain in the butt! Do-able but time consuming. If you can give a shop a CAD file so they don't have to do much CAD work to prep the part that shouldn't cost too much to have cut.  There isn't much $ in material there.

 

[mcooley]

Shipping the parts from the UK from the vendor is the same price as the piece. $50 with the exchange rate plus another $50 to ship it. Kind of sucks. And like I said earlier then I am stuck doing it again for the next frame.

And, yes, once I get the Cad file then it should be smoother sailing. The cut-out shape in the middle does not have to be there. The overall shape is critical as well as the M10X1 hanger hole.

As for bamboo, well, bamboo has natural vibration dampening properties so like carbon it tends to be a smooth ride. Aluminum being the least cushy. Steel still being a good choice though too. Check out Calfee's high-end frames, they're beautiful.

http://calfeedesign.com/adventure/?products=bamboo

This frame will be the second demo frame and unlike the first one I will be road testing it. I am developing it as a workshop to hopefully do with kids in the future. The unorthodox part is the Orthotape, instead, of either hemp or carbon tow for wrapping the lugs. So far it is very sturdy stuff. Probably clear epoxy on the wrap as a finish coat and spar varnish or polyurethane for the bamboo.

I very much like the process which is part design, engineering and sculpture, since, each piece of bamboo is unique.

About 30 hours total per frame.

 

[chris s]

Print a full size pattern, glue it to the aluminum and cut it out by hand with a fret saw. Drill the holes then file to taste. Clock makers do it all the time. No sweat 

 

[teocaf]

Print a full size pattern, glue it to the aluminum and cut it out by hand with a fret saw. Drill the holes then file to taste. Clock makers do it all the time. No sweat

Absolutely!  that is the way i would go for a one-off.  especially given the scope of this unique project.  good excuse to get a 'Knew Concepts fretsaw' and some high quality metal cutting blade.  BUT, i would drill the holes first in the larger blank of metal before doing the cutting, though--it would be easier to handle and clamp the piece for precise holes.  and also all those half circles, as well as any inside corner radius in the other holes can start out as drilled holes as well, then you can cut through them to get the finished look. ( I count 31 holes you can drill first, and that will save you a lot of tight curve cutting)
Then, for the outside and inside edge cutting, cut a bit on the outside of the line and then file or disc sand to your final dimension.