Replies

1. 
   WillGeorge | Aug 27, 2010 01:25pm | #1

   Old metal worker here but hardly ever used aluminium. Mostly stainless steel..

   I fould this and may be of some help?

   http://www.moldmakingtechnology.com/articles/030702.html

   Many more topics out there on the net that could guide you better than I could say about the subject.

   I have cut aluminium on my tablesaw that worked out well. However you said "The chamfer must be perfect".. Would not a Milling Machine be the best option? Not sure about the length of the plate. Router would allow some very long lengths IF you can hold it true enough for your needs. My bet would be a Mill and index for the length needed...

   AND we have no idea about the total size of the plate. Even 3/4 inch will bend a bit if not fully suported on it's entire cutting surface. Or should it be a ?....

2. 
   flairwoodworks | Aug 27, 2010 10:10pm | #2

   I have accidently routed aluminum with a carbide-tipped bit.  I didn't realize it until afterwards.  I would try the chamfer bit, but in small bites.  I don't know what speed to use - I was going at a high speed with a bit about 3/4" diameter (straight bit)

3. 
   lwilliams | Aug 28, 2010 08:23am | #3

   If you have a milling machine use it. Aluminum tends to gall up on the flutes and faces of cutting tools and the higher speed of woodworking tools compounds the problem. A little build-up on the faces of the tooling quickly, very quickly, leads to more. The results can be catastrophic. The flutes and faces of tooling intended for aluminum are highly polished to help control this.