Router for Aluminum and Steel?

Brock Cutlery

Brock Cutlery

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Jan 10, 2015
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I was looking at some knife shop tours and Kool Mist in the shop this morning and found one (Gavko) where two routers were mounted to an aluminum plate, bits up, for routing metal? WTH?


So did some more searching on routing metals. This seems pretty interesting and useful in the knife making world. Especially routing aluminum for tool fixtures and what-not.

Anyone doing this? Opinions?
 
Did he ever show it actually working with the router? If so, I missed where he was using the router. Looks like it might work. I use that type of router bit in a high speed hand grinder for cutting metal.
 
Ken H> said:
Did he ever show it actually working with the router? If so, I missed where he was using the router. Looks like it might work. I use that type of router bit in a high speed hand grinder for cutting metal.
Click to expand...

I couldn't find a video of it actually being used Ken. But I want to go buy one! If nothing, it would be nice for handle work. His setup is nice and compact. Way less than half the size of a standard router table for wood.
It's also got me wondering if I can't use it to cut out the prototype for my horizontal grinder build. I ordered 5/8ths 6061 plates this week, and there are a couple of holes I am wondering how I will cut.
It might be slow going, but this could work.

Could it be used for cutting out choils and such in a steel blade blank? Safety ramifications? What would you use it for?
 
I don't know anything about working with steel but they are great for aluminum. I used to. Build boats and starting about 10 years ago router cut aluminum started to replace waterjet. Any wood working tools work great on aluminum. The only downside is if it starts to stick. Use some wax or any lube every so often to keep the blades clean and they can last for months of heavy use. It can grab a bit harder than wood but there is no grain direction to deal with. I used a power hand plain to shape aluminum too.
 
Fwiw, Routers are used alot machining aluminum architechural stuff at construction jobsites..
Btw,
They run awful fast for rotary files & stones. Not really going to work cutting steel.
A router wont replace vertical mill !
 
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They do make a speed control for routers that might be useful in knifemaking.
Most routers turn too fast for me.
 
I own a couple. The speed range is low 20,000, high 30,000 rpm's. Used it once on aluminum with a 1/8" round over carbide bit. It galled a little, but got the small job done. I don't think I will ever try it on steel - too fast and too light.
 
Harbor Freight used to have a router speed control for around $20. Don't know if they still do.
 
Thanks Ian. I missed that thread. I went and got me the Rigid router and a couple of wood burrs. Need to find the carbide burrs.
I'm going to try mounting it to a 1/4 Al table and see how it goes. I think I'll try to figure out a guide too, even if it's just clamped.
 
Try cheap woodworking router bits. Even a rabbiting bit should work to shape material. Use some sort of lube to coat the cutter to keep from galling. We used to use saw coat if we were going to weld or wax if not. You need the film to keep from brazing to the cutter. Once it sticks it will rip out chunks if whatever blade or cutter you are using. Water is fine but it doesn't form a film.
 
I take it you have never done an 80% lower? Any wood working type router will cut aluminum cleanly, i have no experience using one on steel.
 
I've used carbide tipped roundover bits for aluminum with some success. IIRC, Gavko uses single cut carbide burrs, which I use in pneumatic die grinders all the time for cutting steel.
I actually have an old Makita trim router laying around that I was going to set up for this, just never got around to it.
 
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