Author Topic: Found solution for hobby metal work (Read 8834 times))

Zebra · « **on:** August 25, 2016, 12:22:44 AM »

For anyone looking to machine aluminum billet for a one-time hobby project, I recommend trying a cheap angle grinder.

I got one from Home Depot for $40 and with a $3 grinding wheel, it made short work of a fairly think slab of aluminum billet. You'll go through grinding wheels fairly quickly but they are cheap.

The angle grinder removed material significantly faster than trying to use an end mill bit with a drill press. It was much safer too.

I'm making a bedding block. I haven't finished yet but I've been able to cut a channel in the billet with lines that are straight enough to finish off perfect with some hand files. It's so much quicker than any other rotary tool I've tried.

Rob M · « **Reply #1 on:** August 25, 2016, 04:44:55 AM »

Zebra · « **Reply #2 on:** August 25, 2016, 10:58:17 AM »

Quote from: Rob M on August 25, 2016, 04:44:55 AM

mounted the grinder above a 2 axis vice, u may have no need for filing after.

What did you mount the grinder to?

I was thinking of mounting the grinder on an X Y vise and just using a regular vice for the aluminum billet. I just don't have that much travel in my X Y vise. I have around 4" and the part will be 8". If I turn the part half way then I run into alignment issues and I'm back to filing....

Still, finishing with a file is not too bad. The files I have are cheap but they remove a surprising amount of material for what they are. I wouldn't want to do more than straightening a few edges though...

Rob M · « **Reply #3 on:** August 25, 2016, 11:53:58 AM »

Zebra · « **Reply #4 on:** September 02, 2016, 03:18:23 PM »

I think there are solutions to mount tools on longer tracks but they are more than I want to spend for one off project.

I have been drawing guide lines on the metal and following them with the angle grinder. It works well enough. It will still take me a while to grind a deep (ish) channel in the block of aluminum though.

I have to say, metal work is a lot more fun when your tool grinds properly. Everything I tried with a dremel or drill was painfully slow and no fun at all. A few seconds with a $40 angle grinder and you can see a deep groove cut into the metal.

I've been watching YouTube clips of people using wood lathes on aluminum. It's interesting because they seem to be way cheaper than metal lathes.

quote author=Rob M link=topic=113735.msg1090347#msg1090347 date=1472136838]
i see its for big work.. post pics when u can , and yes i was imagining the small drill press vices which have little travel. I dont have one mounted but was picturing a homebrew jig
[/quote]

Rob M · « **Reply #5 on:** September 02, 2016, 04:04:20 PM »

Rob M · « **Reply #6 on:** September 02, 2016, 04:07:36 PM »

like this with the grinding tool overhead and vice below.. heck you may figure out how to mount other tools to it and spped uup the work while getting a better result.. all speculation

Zebra · « **Reply #7 on:** September 03, 2016, 05:46:09 PM »

That looks awesome!

I could probably make something like that but it's a project in it's own right.

I'll see how I get on with using wood lathes with aluminum. I read that people use lathes for milling too.

The good thing about wood lathes, other than the low price, is that even the cheap ones seem to be made to turn larger pieces so using them to make custom stock might not be an issue. I just need to find out how safe it is using one with aluminum and figure out how to choose a chuck. The wood lathes all seem to come without one and no instructions on which ones would fit etc...

Rob M · « **Reply #8 on:** September 03, 2016, 06:34:40 PM »

Rob M · « **Reply #9 on:** September 03, 2016, 06:50:50 PM »

Rob M · « **Reply #10 on:** September 03, 2016, 07:07:59 PM »

aluminumfetish · « **Reply #11 on:** September 08, 2016, 06:10:31 PM »

Abrasive grinders are not meant to work aluminum. Not a grinding wheel, not a grinding disc. There is an issue of loading the wheel .. it becomes unbalanced and unstable. It's not advisable. With the application of WAX, aluminum can be dressed, but for any major material removal, don't risk it. It certainly is possible but it's not the right way to do it.
http://web.mit.edu/machineshop/Grinder/aluminum.html
Search the web, there a LOT of resources that will say the same thing.

Rocker1 · « **Reply #12 on:** September 09, 2016, 06:57:13 AM »

I have a lathe and a mill now but believe me there was a time when I built all kinds of contraptions to work with and they did the job. My first spring compressor was something to be desired, its a wonder I still have all my body parts. David

sixshootertexan · « **Reply #13 on:** September 09, 2016, 01:38:38 PM »

You'll never see me grinding aluminum. Seen people get hurt doing it.

Zebra · « **Reply #14 on:** October 05, 2016, 04:21:55 PM »

The grinding discs I use on my angle grinder are made for metal. If they work on steel, they are fine on aluminum. It cuts through thick billet like butter. Ok.... not exactly butter but definitely like hard wood.

As for safety, I clamp down the aluminum and clamp the vise to the bench. I wear eye and face protection. I use hand protection. Nothing is 100% safe with metal work but I am satisfied that I have taken enough precautions to make the risk level acceptable for the odd DIY project.

I think the two risks are: the aluminum being launched at you and the disc on the rotary tool flying off and embedding itself in your head. The first is covered but I am far more concerned with the second.

I only use new grinding discs on metal and I regularly stop to make sure they are still tightly attached.

Btw, I had read a bunch of stuff from people who use wood routers on aluminum. They say it works fairly well for shallow cuts and outside detail. I would be more inclined to try that as a DIY milling solution for softer metal than a drill press. Nobody thinks a drill press is a safe metal milling option.

I have a cheap Ryobi drill press. It has the worst build quality of any product I own. There is no way I would get away with doing anything except drilling. It's hardly safe even for that... The people that converted drill presses to mills on YouTube switched out the drill chuck for a metal mill colet. That is the only hack I would consider.

Privateer · « **Reply #15 on:** October 06, 2016, 08:51:20 PM »

Using a cut off wheel or grinding wheel on aluminium?
Just work slow and check the wheel often.
I keep a good wire brush handy to clean things if need be or replace the wheels.

Glad you do wear the proper safety equipment and take care to clamp things properly.
I do demolition work all over the U.S.A. and a grinder is standard equipment for us.
The one thing I hate the most is when a cut off wheel or grinding wheel explodes!

aluminumfetish · « **Reply #16 on:** October 06, 2016, 09:05:27 PM »

I say "do what you like in your own shop!" but don't advise others to do something that is KNOWN to be dangerous and unsafe. If you don't have the right tools, find somebody that does or move along. This thread should be locked.

Privateer · « **Reply #17 on:** October 06, 2016, 09:18:41 PM »

Known to be dangerous is pretty much everything being done in this gate.
Cutting aluminium with a grinder is not that big a deal.
I do it all the time with proper safety equipment and knowing the limitations of my equipment.

The key to it all is to work slow and inspect your gear.
Taking the advise from a interwebz site?
I'd be a outta work Demolition Expert.

aluminumfetish · « **Reply #18 on:** October 06, 2016, 09:30:42 PM »

I know you do that kind of stuff all the time Jeff and that you're smart about it, I just don't think the OP is very responsible to suggest such a thing. I'm old and cranky but I KNOW from almost 20 years of fabricating experience that grinding aluminum is stupid and dangerous. If you want to create parts out of aluminum, use the proper tools. Suggesting that others use an angle grinder to work aluminum into usable parts is just not smart. Sorry if I am offending anybody but just look it up. Do not use an angle grinder to machine aluminum. Period.

Privateer · « **Reply #19 on:** October 06, 2016, 09:43:25 PM »

At first I thought about his original post.
Then I read further.
He's taken the proper precautions as far as I can see.
Could he modify the 1st post? Sure and maybe I'll suggest he does so or I'll add the precautions myself.

I could go through a bunch of threads and come up with reasons to say that's not safe.
But I've been in the business of machinery one way or the other to know being inventive is the key to better ways to do things.
Sometimes that goes against what others think they know.

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Found solution for hobby metal work

Author Topic: Found solution for hobby metal work (Read 8834 times))