help machining a beveled edge on alum flats

[justin caise]

Any ideas on how to bevel the edge of these curvey flat alum motor mounts I hacked out for my GS1000/GS750 project? Just an easy 45 degree on the edge is all I'm after.

All I currently have at my disposal is a drill press with a machinists vise and some assorted mills - or hand files of course. I tried to do some of it by hand but it got a little shoddy in the corners and curves. (Like the GS1000 used to do!)

Any advice is good advice. I'm drawing a blank.






thanks, JC

[marvinsc]

The right tool for the job can be found here. http://www1.mscdirect.com/CGI/NNPDFF...0&PMT4TP=*LTIP

[rapidray]

I don't know if YOU want to try it or not, but on ALUMINUM I use a router with a carbide bit. You could use a "roundover bit" or a "bevel bit". Go to a Home Depot, Lowes, or wood supply store & ask to see router bits. You will need to look for bits that have a bearing on the bottom & it acts as a depth stop. Aluminum is soft enough that a router will do it no problem. You just need to come up with a way to clamp the pieces down. Ray.

[Hammered]

I don't know if YOU want to try it or not, but on ALUMINUM I use a router with a carbide bit. You could use a "roundover bit" or a "bevel bit". Go to a Home Depot, Lowes, or wood supply store & ask to see router bits. You will need to look for bits that have a bearing on the bottom & it acts as a depth stop. Aluminum is soft enough that a router will do it no problem. You just need to come up with a way to clamp the pieces down. Ray.

Great idea. Ive used the same method. Much cheaper than buying a Mill. You could also find a machine shop locally and have that done. Will cost you as they charge setup times and all.

[tkent02]

Just curious, those look about the same size as the original ones, but they were steel.
Are those going to be strong enough?

[posplayr]

Get one of these

and you will be in business.

http://www.harborfreight.com/cpi/cta...emnumber=94276

Alum is soft, but unless the material is held firmly the bits will grab and fling the part. I have a large table top drill press and use a vice like the above.

Pos

[GQROD]

A router with carbide would do it. It will get hot though.

[rapidray]

A router with carbide would do it. It will get hot though.

Actually, it doesn't because aluminum disipates heat so quickly & he isn't removing much material. Ray.

[tejasmud]

True.

One thing I would like to know is how you going to chuck/clamp up on them to get a router on them? They look small. Possibly a router table would work.

What is wrong with them as they are? They look good.

A belt/drum/disc sander does wonders to finish out parts. Knock burrs off.....

You going to paint them, anodize them?

Are they really going to be seen?

Workmanship and pride.

I know.


Don't answer any of the questions. Just thoughts.

Sand them down, polish them, clear coat........would look good also....

[Jethro]

If I were doing this at my house I would probably use my bench grinder and a lot of patience... and it would probably look horrible.

[Greg B]

DO NOT grind aluminum on a bench grinder. Aluminium will load the wheel, clogging it. After that, there is a HIGH probability of the wheel exploding, as heat buidup will cause the aluiminum embedded in the wheel to expand and blow the wheel apart violently.
Better to use a belt sander. Or a dremel with a SANDING drum.

[Commodus]

If I were doing this at my house I would probably use my bench grinder and a lot of patience... and it would probably look horrible.

Bench grinder on aluminum? Only if you have the right wheel.

[Commodus]

Any ideas on how to bevel the edge of these curvey flat alum motor mounts I hacked out for my GS1000/GS750 project? Just an easy 45 degree on the edge is all I'm after.

All I currently have at my disposal is a drill press with a machinists vise and some assorted mills - or hand files of course. I tried to do some of it by hand but it got a little shoddy in the corners and curves. (Like the GS1000 used to do!)

Any advice is good advice. I'm drawing a blank.






thanks, JC

File 'em. It'll take some practice but skill with a file is something worth developing.

[rustybronco]

my suggestion, chuck a sanding drum in the drill press and tilt the table 45 degrees.\

File 'em. It'll take some practice but skill with a file is something worth developing.

definitely a worth while skill.

[tejasmud]

DO NOT grind aluminum on a bench grinder. Aluminium will load the wheel, clogging it. After that, there is a HIGH probability of the wheel exploding, as heat buidup will cause the aluiminum embedded in the wheel to expand and blow the wheel apart violently.
Better to use a belt sander. Or a dremel with a SANDING drum.

Belive it or not, I have seen a wheel explode. I was not near it, or the one who loaded it. Always best to start a grinding tool up and walk away a few feet to the side until it gets up to consistant RPM.

Never blow compressed air into a wheel either.

For tight spaces to do clean up, smooth, or radius I have used a grinding tip in a die grinder, but dress the tip about every minute or so. They don't last long enough to explode. This is only after the bulk of the material has been removed with a mill. Die grinder carbide burrs will load up as well on aluminum. Want to mess up a good burr try it on aluminum.

Best is sanding, or use of a file if the part can't be chucked up on.