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the AL cuts about the same as say maple or oak, not too hard. Use a fresh bit. As far as jumping around, I was just real careful and didn't try to bite off too much at once. Yes, it is kind of nuts and risky I suppose. Once you get a bit of depth established the bit will stay trapped. The secret is to not work over to your finish cut line until the final full depth cut, and work the direction of the bit, not against it, making many gentle passes.
My 1/2" dia. bit would clog quickly, and then it wanted to walk all over rather than cut. The bigger dia. bit wouldn't clog at all and has a higher rotation speed. The AL didn't seem to dull it much at all. My carpenter experience says don't even mess with any products made by Vermont/American. It's all cheap crap. Buy a Bosch or Delta bit which may run $28, but will last. I've had Vermont/Amer. bits literally wear out in 30 seconds cutting wood no less (sometimes you're at the lumberyard and have no choice)
Wood templates can be made that guide the base of the router and prevent runaway. If you came up with a pattern for Tracy's PSRU (that he would approve) I could make such a template and others could use it too. How much weight savings do you think you can get from all of this?
Kevin Lane Portland, OR
e-mail-> n3773@comcast.net
----- Original Message ----- From: "Ernest Christley" <echristl@cisco.com>
To: "Rotary motors in aircraft" <flyrotary@lancaironline.net>
Sent: Friday, March 04, 2005 1:44 PM
Subject: [FlyRotary] Re: hand router milling
kevin lane wrote:
Whoa, don't get me in trouble with Tracy.
Kelly, it is I that has been cutting on a PSRU. I've got some pics in my camera that I'll post tonight.
I was referring to the engine mounting plate, not the PSRU plate. I'm sure there is extra weight in his solid plate, but I don't have the knowledge to modify it. Much of the engine mount plate is simply a shim. That is what I was cutting away.
Kevin, what sort of bit did you use on the router to get the initial rut? A 1" wide rut would seem excessive. And how did you keep the bit from trying to ride up onto the top of the work rather than maintaining a constant depth?
I'm working on wing ribs right now, but in a week or two I'll be doing exactly what you've done to my bellhousing.
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