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+--- Thread: How can I cut out 3 circles of 1/8" Aluminum circle (/showthread.php?tid=2708)
How can I cut out 3 circles of 1/8" Aluminum circle - 1-LVDCPN - 04-27-2018
Hello Everyone,
I could use your help. I need to cut out 3 circles of 1/8" Aluminum. They are 7-1/2" diam. with a 2" hole in the center and a 4 or 6 hole bolt circle at 6-1/2". I have tried using a Scroll saw with Aluminum blades as well as other types of blades. They just snap. I'm feeding it about a 1/16" a min. (very slow). I have adjusted the tension without luck. My lathe won't swing that large. All I have at my disposal is a bench belt sander, 8" bench top drill press & Aluminum circle I can't afford to have it done. I need to come up with a way to get them cut myself. The parts are 7-1/2 square to start with. If I could figure out a way to cut the corners off I could use the belt sander to get it round. I thought about putting an end mill in the drill press and using a pin to rotate the part on. But I'm a little leery about doing that. The parts will have a 2" hole in them all said and done. I guess I could cut the corners off with a hack saw a little at a time until it is roughed out. But if someone has a better idea I'm all ears.
Thank you,
RE: How can I cut out 3 circles of 1/8" Aluminum circle - aluhm - 04-27-2018
Since the material is fairly thin, I would try this approach:
a) Use double sided tape and stick the plate onto a piece of plywood about the same size.
b) Mount the plate/plywood onto your lathe's faceplate with wood screws from behind using flat head screws big enough to catch both sides of the slot, yet short enough not to touch the aluminum.
c) Trepan the OD. A parting tool may work on this diameter but you may need to make up a correct trepanning bit. Take it real easy, using the compound to advance the bit.
d) Drill/bore out the ID.
e) Use a heat gun to warm up the plate which will help with removal.
Good luck.