Crazyraceguy
Member
- Joined
- Oct 16, 2015
- Messages
- 4,887
I get stuck working with this stuff far more frequently than I would care for. It's not particularly horrible if it is used correctly, meaning flat work and never adjacent sides coming together. However, the local architects do seem to care to follow those rules. This job has three different colors of this material, in a few areas. I did another phase of this project months ago with the adjacent panels issue. This time it's the bending it around a radius bit. It's a multi-layer product, with a thin phenolic backing, which is not really a fan of bending. It's a 16" radius, so it might work, haven't tried it yet.
The challenge for yesterday was the flat sections. These were made with some special lightweight plywood, for two reasons. They hang overhead on metal Z clips and have the added weight of the metal.
This lightweight stuff is made from 2 outer layers of 1/8" Poplar plywood with a 1/2 foam core. This presented a problem itself. Everywhere these panels meet each other there is a 1/4" X 1/4" rabbet as a reveal. Obviously, this is a problem. When you cut a 1/4" rabbet, on the edge, you cut into the foam too.
The simple work-around was to make a border around each panel with MDF. I cut a groove around the panel edges and a mating tongue on the MDF strips, making a good solid attachment and a proper surface for the reveal/rabbet.
So far, so good. Now for the real challenge. The only way to route this metal laminate is with a down-spiral bit. Straight bits raise a ridiculous burr on the surface, which is a huge deal. Removing/filing at it is impossible without damaging the anodizing, so down cut only. You cannot cut the rabbet first. There is no way to trim the laminate over that rabbet, so they both have to happen at the same time. On straight-sided panels, this is no big deal either. OF1010, modified edge guide, plenty of extraction speed, and a careful hand, no problem. It's the 16" radius corners that are the challenge. A normal rabbet bit is a no-go, back to the burr thing. So, a down spiral bit needs to do this.
My first thought was to use one of my Bosch Colt routers, since they have a single-wheel follower attachment, but it wouldn't off-set far enough for a 1/4" rabbet, using a 1/4" bit.
The only down spiral bits I have are all the solid carbide variety with the shank and cut diameter being the same. I have bigger bits, but no way to hold them in the Colt. I was just about to fabricate a follower for something, then I remembered the Makita has a follower bearing attachment too, and the collet to hold an 8mm bit. That did it, there was just enough off-set to make it work.
The apprentice/kid was truly inspired/finally understanding the "having so many tools, because I have to deal with everything"
I could "order something" and wait a day or 2, but the job needs to go. This kind of thing never happens on a job that will sit for a week or two. [unsure]
The challenge for yesterday was the flat sections. These were made with some special lightweight plywood, for two reasons. They hang overhead on metal Z clips and have the added weight of the metal.
This lightweight stuff is made from 2 outer layers of 1/8" Poplar plywood with a 1/2 foam core. This presented a problem itself. Everywhere these panels meet each other there is a 1/4" X 1/4" rabbet as a reveal. Obviously, this is a problem. When you cut a 1/4" rabbet, on the edge, you cut into the foam too.
The simple work-around was to make a border around each panel with MDF. I cut a groove around the panel edges and a mating tongue on the MDF strips, making a good solid attachment and a proper surface for the reveal/rabbet.
So far, so good. Now for the real challenge. The only way to route this metal laminate is with a down-spiral bit. Straight bits raise a ridiculous burr on the surface, which is a huge deal. Removing/filing at it is impossible without damaging the anodizing, so down cut only. You cannot cut the rabbet first. There is no way to trim the laminate over that rabbet, so they both have to happen at the same time. On straight-sided panels, this is no big deal either. OF1010, modified edge guide, plenty of extraction speed, and a careful hand, no problem. It's the 16" radius corners that are the challenge. A normal rabbet bit is a no-go, back to the burr thing. So, a down spiral bit needs to do this.
My first thought was to use one of my Bosch Colt routers, since they have a single-wheel follower attachment, but it wouldn't off-set far enough for a 1/4" rabbet, using a 1/4" bit.
The only down spiral bits I have are all the solid carbide variety with the shank and cut diameter being the same. I have bigger bits, but no way to hold them in the Colt. I was just about to fabricate a follower for something, then I remembered the Makita has a follower bearing attachment too, and the collet to hold an 8mm bit. That did it, there was just enough off-set to make it work.
The apprentice/kid was truly inspired/finally understanding the "having so many tools, because I have to deal with everything"
I could "order something" and wait a day or 2, but the job needs to go. This kind of thing never happens on a job that will sit for a week or two. [unsure]
