Thread: cutting a slot in aluminium

Do you have access to machine tools.

If you have access to a router it is relatively to make most of this cut in aluminium.

Firstly I would arrange to get the aluminium oversized and cut the slot first and then cut the aluminium to size around the slot - that way you get the slot exactly where you want it.

Then get a large piece of 12mm thick MDF and using big pieces of double sided tape stick the ally to the mdf.

Drill a starting and finishing hole in the metal/MDF slot big enough to accept the router tip.

Clamp the MDf to your bench and clamp a straight piece of wood to act as a fence along which to run the router

Rout the slot and finish the ends with file.

To help the router cut in Ally liberally coat the router tip with candle wax and rub wax along the area which is going to be cut.

Practice using a thin sheet of MDF.

I use routers and tables saws on Ally all the time. Take it slowly and use wax (or metho when the motor is some distance away) for a lubricant.

hello thanks for your replies . very kind of you.

i only have access to a mains electric hand held drill at present. a fine blade hack saw and other usual common tools. i was wondering if there was a tool i could buy? like a saw file or a punch type tool? or a special drill bit. sorry i did not say before.

thank you for you time.

Do you have files that will go in a 3.5mm slot?
If so, start by drilling a row of 2.5mm holes about 15mm long. File them to make a short slot. Us a vice or clamp a piece of wood/steel along the edge of the slot you want to support the sheet. Put a hacksaw blade through the slot you made(you may be able to use two blades on one saw if the cut they make is less than 3.5mm). Carefully cut down the middle of the slot. Clamp a piece of steel along one edge of the slot(a cheap steel rule if you have to). carefully file down to the rule. repeat on the other side of the slot.
Do you know what draw filing is?

Hope this helps you out.

Stuart

hi thanks

that's a great idea to clamp a steel ruler along the edge of the slot, i was really worried i would make a wobbly line. i have one of those in my tool box. Is draw filing is when you draw the file toward you in a stoking fashion?

thanks again for your help : )

Draw filing is when you hold the file in both hands (one hand on handle and the other the other end of the file) and have the long axis of the file at approx 90deg to the long axis of the job. File back and forth along the long axis of the job.
Instead of maybe wrecking your rule you could get 2 straight bits of angle and clamp the job between them in the vyce. this will give more support to your sheet and give you a straight edge to work to.n The very first thing to do on this job is mark it out so you can see where you are going with it.

bollie7

You could use an abro file, not to sure on the spelling

If I were to do this I would clamp the aluminum to a piece of wood then clamp the lot to my table saw then slowly raise the blade to cut the slot. I am thinking off the top of my head that my blade is about 3.5mm thick.

Squirrel

Hi Harps,

Firstly, what part of the Motherland are you from?

Secondly, what is it you are going to make from this training exercise?

Thirdly, looking at your drawing it appears that the slot is closer to one end of the strip than the other, yet there is only one dimension 15mm!!

I have a few ideas that will help if you can reply to my questions

Cheers
MH

Originally Posted by bollie7

Draw filing is when you hold the file in both hands (one hand on handle and the other the other end of the file) and have the long axis of the file at approx 90deg to the long axis of the job. File back and forth along the long axis of the job.
bollie7

Just checking on draw filing procedure - please advise if I'm wrong:
A single cut file is necessary for draw filing, I think. Cuts are only in one direction, not back and forth?

Jordan

When draw filling you use the file sideways.

For aluminium that's only 1.25mmm thick, you could even scratch your way through using a tungsten tipped laminate scoring tool.

For that sort of hole, I'd prefer a nibbling tool over a drill, though.
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