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Old 12-15-2007, 08:21 AM   #1
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Default cutting aluminum with dremel

what atachment do you use to cut metal with the dremel? i want to make a custom chassis for my wk.
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Old 12-15-2007, 08:43 AM   #2
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Originally Posted by bigblazerboy View Post
what atachment do you use to cut metal with the dremel? i want to make a custom chassis for my wk.
if you must use a dremel; use the metal cutting disc.

I would highly suggest a band saw though.
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Old 12-15-2007, 09:17 AM   #3
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thanks. i dont know any where that has one and my dad doesnt have one, but my school tech class has one that we used last year to cut wood.

unless he knows somwhere that has one, we will probably have to use the dremel, unless someone can cut it for me.
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Old 12-15-2007, 09:28 AM   #4
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Just a little warning....

It will be very very slow going. You will need a lot of patience and plenty of cut off wheels (good thing they are cheap). I used a jig saw to cut my chassis and it wasn't too bad. Much faster than the dremel.

Good luck!

-Goo
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Old 12-15-2007, 09:38 AM   #5
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thanks that might work. i bet my dads got one of those. hes got a lot of tools.
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Old 12-15-2007, 11:12 AM   #6
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make sure you are using a metal blade on it... a wood blade will blow apart within seconds.
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Old 12-15-2007, 03:18 PM   #7
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the one im talking about is at my schools tech. lab. might just get some c channel or L angle metal.
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Old 12-15-2007, 03:40 PM   #8
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Originally Posted by bigblazerboy View Post
the one im talking about is at my schools tech. lab. might just get some c channel or L angle metal.
I dont care where it is at. If it has a wood cutting blade on it and you stick a piece of aluminum in there.... sparks will fly.
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Old 12-15-2007, 04:07 PM   #9
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X2 what Mr. Pink says! The teeth on a wood cutting blade are spaced to far a part.

Do you happen to have a hack saw? That would work for roughing out. For internal pockets you have to drill holes for the saw blade. Disassemble the hack saw then reassembly the hack saw so it's inside the pockets and saw them out. A jig saw would be better suited for this.
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Old 12-17-2007, 10:01 AM   #10
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I've built many small, flat aluminum parts using a dremel with cutoff discs, jigsaw, hacksaw or a combination of the three. Of these three, the jigsaw is the fastest, but as others have said, make sure you get blades meant for metal (they have many more teeth per inch than a wood blade). A bonus I found is that they're often suitable for plexiglass. I'm always chopping up lexan.

The dremel works, but it's very slow, and one little slip can leave a nasty gash in the metal. Expect to be breaking lots of the cutting discs. If you go this way, use the heavy duty cutoff discs. I usually use my dremel for small stuff only.

Hacksaw actually works relatively well, but has limited room for cutting before you hit the backside of the hacksaw.

For all three, prepare to invest in a set of metal files to finish off the edges (both in terms of cleaning up the cuts, and finishing to make sure you don't have sharp edges).

Honestly, if you're going with a TVP design for your WK, I'd just use delrin or 1/4" lexan, or even cutting board material. Once you cross brace the TVP with spacers and your skid plate, you'll find it will have plenty of strength. All of the above are much much easier to work with as compared to any metal, even soft ones like aluminum.

Finally, you sound like a young guy. As I was that age once and prone to doing stupid things, don't forget to take proper safety precautions! Safety glasses are a must.
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Old 12-17-2007, 02:12 PM   #11
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im 13, i get my dad to help me on most things, i think i might make a tuber with him, or some plates, still deciding.
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Old 12-17-2007, 02:39 PM   #12
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Just take your time and wear eye protection. It will be a good project for you and him. You can get great results with any tools you have there if you plan out what you're going to do and take your time
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Old 12-17-2007, 03:05 PM   #13
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Quote:
Originally Posted by bigblazerboy View Post
what atachment do you use to cut metal with the dremel? i want to make a custom chassis for my wk.
You can use a jig-saw,just buy the finest pitch blade you can find.Fine meaning with the most teeth per inch.Works very well up to 1/8 or 1/4 inch thickness.Squirt a little WD -40 on it for cutting fluid.
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Old 12-18-2007, 05:48 PM   #14
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I think Ill get myself a jig saw .. any recomendations?
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Old 12-19-2007, 07:01 AM   #15
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I think Ill get myself a jig saw .. any recomendations?
Spend the money for one with varible speed.I bought one at Walmart for under $30. Try and buy a wide selection of different pitch blades,so you always have the right blade for the right material.
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Old 12-21-2007, 10:37 PM   #16
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Quote:
Originally Posted by sLeigh_P View Post
X2 what Mr. Pink says! The teeth on a wood cutting blade are spaced to far a part.
x2 thats a death wish look at the difference.
wood.

metal


see the teeth? they are different

wood is softer then metal. making it easy to cut with larger more apart teeth where as metal is hard and many small teeth work better.
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