Remove advertisements
Results 1 to 10 of 10
  1. #1
    scorch's Avatar
    Join Date
    Apr 2015
    Location
    Oakdale, MN
    Posts
    55
    Thanks
    8
    Thanked 63 Times in 26 Posts

    Router Mill for Aluminum (Poor Man's Milling Machine)

    After hand working a bunch of sand cast parts for my Gingery lathe I decided there must be a better way. So I built up a little mill consisting of a wood frame, cross slide vice and standard router for preparing the surface of cast aluminum parts.

    Here is a link to a .

    Assembled Mill:
    Router Mill for Aluminum (Poor Man's Milling Machine)-overview.jpg
    Router Removed (exposing cross slide vice):
    Router Mill for Aluminum (Poor Man's Milling Machine)-vice_pic.jpg
    Closeup with workpiece shown through router hole:
    Router Mill for Aluminum (Poor Man's Milling Machine)-closeup.jpg


    EDIT: Added details below this line.

    One of the comments Wmrra13 made below made me think of some additional details that might be interesting.

    The router was mounted to a ring of aluminum which was in turn bolted to piece of wood that made up the top of the router mill. The ring of aluminum was made from the bottom of a nonstick aluminum frying pan. In the picture below the top plate of the mill is leaning against the back wall so you can see the black, non-stick (Teflon) coated, side of the frying pan.
    Router Mill for Aluminum (Poor Man's Milling Machine)-cover.jpg

    I used a high speed high helix bit specifically designed for high speed aluminum machining for most of my cuts but I also used regular wood cutting bits if I needed a special feature like inside corner rounded.

    I usually sprayed the work piece with WD-40 to prevent the chips from sticking to the bit. The WD-40 seemed to work well for that application.
    Last edited by scorch; 04-14-2015 at 04:44 PM. Reason: Adding details

  2. The Following 3 Users Say Thank You to scorch For This Useful Post:

    blkadder (04-14-2015), GlennR (04-12-2015), kbalch (04-13-2015)

  3. #2
    Content Editor Altair's Avatar
    Join Date
    Aug 2013
    Posts
    667
    Thanks
    119
    Thanked 80 Times in 68 Posts
    Brilliant idea. Looking forward to seeing the finished lathe!

    Al

  4. #3

    Join Date
    Mar 2015
    Location
    Boone, NC
    Posts
    28
    Thanks
    4
    Thanked 13 Times in 8 Posts
    Good solution.

  5. #4
    Administrator
    Join Date
    Jun 2012
    Location
    Clermont, FL
    Posts
    5,034
    Thanks
    2,275
    Thanked 460 Times in 354 Posts
    Thanks scorch! I've added your Router Mill for Aluminum to our Machining category, as well as to your builder page: scorch's Homemade Tools. Your receipt:


  6. #5
    Wmrra13's Avatar
    Join Date
    Jan 2015
    Posts
    38
    Thanks
    26
    Thanked 10 Times in 5 Posts
    Scorch,

    I just looked at your site - lots of cool stuff!

    I'd be interested in seeing more about your aluminum casting tools and techniques.

    Your router mill is cool and would be even better if the top plate that that the router is mounted to was made out of polycarbonate or something else transparent. Still, I'm not sure why you need it since you have a really cool CNC router setup?

    Cheers,
    Tyler
    Last edited by Wmrra13; 04-14-2015 at 11:12 AM.

  7. #6
    scorch's Avatar
    Join Date
    Apr 2015
    Location
    Oakdale, MN
    Posts
    55
    Thanks
    8
    Thanked 63 Times in 26 Posts
    Thanks Wmrra13,

    I do plan to post more of my stuff. I am pondering building a minimalist foundry to post. It is pretty shocking how much you can do with very little investment.

    You are right I don't really need the router mill anymore. In fact I don't have it. I sold off the cross slide vice and have since mounted the router motor to my CNC mill (using a cast aluminum part). I didn't have the CNC mill when I made the router mill.)

  8. #7
    Wmrra13's Avatar
    Join Date
    Jan 2015
    Posts
    38
    Thanks
    26
    Thanked 10 Times in 5 Posts
    Quote Originally Posted by scorch View Post
    Thanks Wmrra13,

    I am pondering building a minimalist foundry to post. It is pretty shocking how much you can do with very little investment.
    I just bought the Gingery casting book. I think that's one of my next projects.

    Quote Originally Posted by scorch View Post
    ...since mounted the router motor to my CNC mill (using a cast aluminum part). I didn't have the CNC mill when I made the router mill.)
    That's what caught my eye.

    Thanks,
    Tyler

  9. #8
    scorch's Avatar
    Join Date
    Apr 2015
    Location
    Oakdale, MN
    Posts
    55
    Thanks
    8
    Thanked 63 Times in 26 Posts
    FYI, I added an additional picture and a little more description to the original post above. (for future readers)

  10. #9
    blkadder's Avatar
    Join Date
    May 2012
    Posts
    24
    Thanks
    66
    Thanked 5 Times in 4 Posts
    Okay, now I need to go buy a router. Amazing work. Thanks for posting.

    Ron
    ...Semper Fidelis...

  11. #10
    Content Editor DIYer's Avatar
    Join Date
    Aug 2013
    Posts
    3,024
    Thanks
    217
    Thanked 414 Times in 375 Posts
    That's a great post, scorch! Thanks for the idea.


    Post your reply!
    Join 20,941 of us and get our 50 Must Read Homemade Tools eBook free.



    50 Must Read Homemade Tools

Thread Information

Users Browsing this Thread

There are currently 1 users browsing this thread. (0 members and 1 guests)

Bookmarks

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •