Tips for working with aluminum

[Cheese]

The first thing I'd do is to cover the top surface of the aluminum plate with a self adhesive plastic film. It could be a plastic film made specifically for that purpose or it could be simple plastic tape like what's used to seal vapor barriers, house wrap or foam panels. Any aluminum chip that gets adhered to the cutting tool, will usually spin around on the naked aluminum surface and damage it.

I'd remove the bulk of the material with a holesaw. Then come back and clean up the holes using the router and a lubricant like Tap Magic for aluminum. I wouldn't use a vac with the router as you really don't want that cutting fluid in the dustbag. Besides, you'll have removed 90% of the material with the holesaw so there won't be a large amount of aluminum chips.

 

[rst]

I'm totally in agreement with Cheese's procedure.  It's how I prep commercial aluminum doors, framing and jigs and have for 44 years.

 

[Michael Kellough]

When cutting aluminum and copper with Shaper Origin use these thin PET plastic sheets as a buffer to prevent drag and scoring of the Origin/router base. at 1mm thick the plastic raises the machine just high enough to avoid the burrs created by milling the soft metals. Cutting the plastic does raise burrs but they can be easily scraped off and still protect the workpiece.

 

[Cheese]

Ran across these today, they could be very helpful for some applications. They come in 21 different sizes from 1/8" thick to 3/4" thick. The weird alloy number caught my attention, I don't ever recall seeing a 6101 alloy before. The alloys 6101 & 6061 are virtually the same except for electrical & thermal conductivity values.

[attachimg=1]
https://www.onlinemetals.com/buy/aluminum/0-125-x-0-75-aluminum-full-round-edge-6101-t61/pid/18141

 

[Cheese]

This just popped up today...it really does look like a great trial package. The Cubitron discs usually sell in the $8 to $10 range so 15 samples plus a face plate back-up pad that I recently paid $25 for seems like a steal for $59.

I'll order a sample pack tomorrow.
https://www.rshughes.com/p/3M-Cubit...w0xaHZqF_BsAzSPy0hnIgIE0u3_pK6iBxOLY0o.WjJzt2

Five each of 3M™ Cubitron™ 3 - 1182C, 4-1/2 in x TN, 36+ Quick Change Fibre Discs
Two each of 3M™ - 769F, 4-1/2 in x 5/8 in-11 40+, T27 Quick Change Flap Discs
Two each of 3M™ Cubitron™ 3 - 4-1/2 in x 1/4 in x 5/8 in-11, T27 Quick Change Grinding Wheels
Two each of 3M™ Cubitron™ 3 - 4-1/2 in x 0.045 in x 7/8 in, T27 Cut Off Wheels
Two each of Scotch-Brite™ Clean and Strip XT Pro - 4-1/2 in x 5/8"-11, Extra Coarse, T27 Quick Change Discs
Two each of Scotch-Brite™ Light Grinding and Blending - 4-1/2 in x TN, Coarse Quick Change Discs
One 3M™ 4-1/2 in, Red Ribbed Extra Hard, Fibre Disc Back-up Pad

 

[Cheese]

Heck, I just ordered a sample pack tonight before they're gone. That happened a few years ago with the Cubitron II sand paper sample packs.  [tongue]

 

[festal]

Heck, I just ordered a sample pack tonight before they're gone. That happened a few years ago with the Cubitron II sand paper sample packs.  [tongue]

[member=44099]Cheese[/member] are you going to use it with your festool grinder?  description says right angle grinding.  but looks like regular 4 1/2" discs

 

[Cheese]

[member=44099]Cheese[/member] are you going to use it with your festool grinder?  description says right angle grinding.  but looks like regular 4 1/2" discs

Absolutely  [smile]  the AGC will accept discs of 4-1/2", 5" & 6".

Here's a 6" x .045" cutoff disc and a 5" abrasive disc I use to sharpen lawnmower blades and shovels.

[attachimg=1]

[attachimg=2]

 

[festal]

[member=44099]Cheese[/member] are you going to use it with your festool grinder?  description says right angle grinding.  but looks like regular 4 1/2" discs

Absolutely  [smile]  the AGC will accept discs of 4-1/2", 5" & 6".

Here's a 6" x .045" cutoff disc and a 5" abrasive disc I use to sharpen lawnmower blades and shovels.

[attachimg=1]

[attachimg=2]

Perfect. thank you

 

[festal]

[member=44099]Cheese[/member] have you ever tried pferd combiclick? https://fireballtool.com/products/pferd-48194-combiclick?_pos=32&_fid=160a87cdd&_ss=c

how does it compare to cubitron 3 kit?

 

[Cheese]

[member=44099]Cheese[/member] have you ever tried pferd combiclick? https://fireballtool.com/products/pferd-48194-combiclick?_pos=32&_fid=160a87cdd&_ss=c

how does it compare to cubitron 3 kit?

No, I have not, however I do like the regular Pferd abrasives especially their flap discs. Looking at that Pferd Combiclick kit, I find the similarities between the Pferd kit and the 3M kit pretty astounding.  [big grin]

I just received the 3M kit yesterday and I'll post some photos later today. Some clever packaging was used as a marketing tool.

 

[festal]

[member=44099]Cheese[/member] have you ever tried pferd combiclick? https://fireballtool.com/products/pferd-48194-combiclick?_pos=32&_fid=160a87cdd&_ss=c

how does it compare to cubitron 3 kit?

No, I have not, however I do like the regular Pferd abrasives especially their flap discs. Looking at that Pferd Combiclick kit, I find the similarities between the Pferd kit and the 3M kit pretty astounding.  [big grin]

I just received the 3M kit yesterday and I'll post some photos later today. Some clever packaging was used as a marketing tool.

Mine arrived yesterday as well.  Packaging is pretty neat. like a mini carton tool box lol

 

[rst]

I ordered a Pfred Paint and Prep combo kit from Zoro after watching a YTube video using 50mm polishing kit.  I put that the polishing kit in my Amazon cart for future reference.  I’ve used 3M 1, 1 1/2 and 2” in the past.  I have a variety of sizes and uses of discs and abrasive brushes in an original Tanos I.

 

[tsmi243]

OK, ya got me.  Bought one.  Now how does this part work???  It matches the 5/8-11 threads, but that can't possibly go direct on the grinder, can it?  None of the other pieces in the kit hold it.