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Comment by Jesse Hartman on February 15, 2013 at 2:44pm

Thanks clint

Comment by Clint L Gosch on February 15, 2013 at 2:30pm

Hi Jesse.  Used a carbide laminate trim bit.  If you have not seen these they look like a straight router bit with a ball bearing on the top. Menards or Hope Depot should have them. I used a router table and made a curtain out of garbage bags to contain the flying chips.  I also recommend rough cutting the parts to within 1/4" of final size before running them across the router, limits the kick back potential (mind your feed direction also, I managed to launch a part across my workshop).  I was also concerned with overheating the aluminum during cutting, so I applied candle wax to the aluminum, acted as a lube for cutting and also as an indicator as to how hot the piece was getting ahead of the cut, if the wax melted an inch ahead of the cut, I reduced my feed rate. I finished the parts with a flat file and scotch brite. Hope this helps! 

Comment by Jesse Hartman on February 15, 2013 at 12:16pm

Hey Clint.  Did you use a router bit to trim these? If so what kind and where to get one?