Can you use a router to mill a small channel in some thin (1/8") aluminum? Or is this a bad idea?

I have seen wood routers used on aluminum. No idea if it's a good idea or not.

Could be a terrible idea. You're going to have to control those forces...

Yes. Provided you have the right bit. Those 80% lowers usually come with a small end mill that you put in your router to mill it out.
You can cut aluminum with your table saw/miter saw as well. I used to weld aluminum at my last shop and we used a commercial chop saw made for wood and a regular table saw on aluminum daily

Aluminum is soft, even a file or sandpaper will make short work of it. A router and the right bit could easily do it.

The right table and jig/fences would be key, I think, just holding everything securely and square.

It would be a challenge.
I wonder if the router speed would be too fast.

do it all the time, if you have a variable speed router it will help. buy the correct bit, and I use aluminum tapping fluid.

Speed was my concern as well. You might be better off with a variable speed drill press the proper bit and cutting fluid.

We have CNC routers at work that chew through aluminum effortlessly.

Just cut in layers and lube each pass.

Make you a jig and buy the bit and everything will be fine.

Depends on the grade of aluminum. But for most stuff that you would buy at a local hardware store of metal supply, yes. Take all the right safety precautions. Make sure you have a jig or you WILL ruin the piece. Wear good eye protection as it will throw chips all over the place.

But yeah. Several places that sell 80% lowers have instructions or jigs to facilitate milling those out with routers.

Take proper precautions. aluminum chips will damage your eyes very easily. Also aluminum dust is explosive if ignited.

quote:

Originally posted by PeteF:
Take proper precautions. aluminum chips will damage your eyes very easily. Also aluminum dust is explosive if ignited.

Oooh a thermobaric bomb! I wanna watch!

quote:

Originally posted by cne32507:

quote:

Originally posted by PeteF:
Take proper precautions. aluminum chips will damage your eyes very easily. Also aluminum dust is explosive if ignited.

Oooh a thermobaric bomb! I wanna watch!

Mix powdered Al with FFFFG blackpowder.

Poooomm!!!

For metal/aluminum a router is extremely fast. Clamping the work and light cuts is the way to do it. If the cutter grabs the work either the work will go flying or the router will. Both could be a bad thing. Chips will be flying with extreme speed as well. They will cut you and/or blind you.

If you happened to have a steel splinter in your eye the doctor might take it out with a magnet. This is not possible with aluminum. Removal may be a bit more primitive.

Practice on some scrap pieces first. That will be worth the time, guaranteed. I believe the cutter must be carbide so it won’t weld aluminum chips to the cutting edge. This is also why lubricant is important.

IIRC cutting speed for aluminum is about 700-800 surface feet per minute. That is about 3200 rpm for a 1/4” router bit. A woodworking router runs in the range of 20,000 rpms. While the router will do the job, please be very cautious and respect the power and speed of the machine.

When it is done the job may not be pretty. Even smaller cuts/passes with more of them will help the quality.

At one of my previous employers, the CNC router station utilized the big 3-1/4? HP Porter Cable router to cut 6061 Aluminum plate to at least 3/8" thickness. No memory with regard to bit material, rpm's.

In other words, don't do it free hand. You'll shoot yer eye out.

quote:

Originally posted by Rightwire:
Speed was my concern as well. You might be better off with a variable speed drill press the proper bit and cutting fluid.

Using a drill press as a router/mill is iffy.

They aren't designed for sideways loads on the bit. Besides the possibility of damage to the drill press, drill press chucks aren't actually attached to the spindle at all, they just have a taper on the back that presses in to the spindle and kind of locks in place. Putting sideways load on a bit has a tendency to make the chuck literally just fall right out of the drill press.

quote:

Originally posted by PeteF:
Take proper precautions. aluminum chips will damage your eyes very easily. Also aluminum dust is explosive if ignited.

AND, VERY harmful if you breath the dust in when you cut it. Wear a particle mask when you cut it.

Thanks for all the feedback. I think I'll look at other options. I'm kind of fond of my eyes and lungs