How to Cut Aluminum with a Router

You may think of your router as a tool only for woodworking, but Chris Marshall explains how you can use it for metal pieces as well. He shows the jig he used to set up the cut and explains the bit and router setup to make the cuts.
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[@nccyr1]

Good stuff! I am watching this in 2024; good tutorial videos don't age. Thank you for this demo, it gives me confidence I can use my tools to do the same.

[@Branhawk]

I’m a sheet metal fabricator, and never thought of this. So cool and clean well done sir 👏👏👏

[@fernandoescobar1594]

Awesome! I never think that is possible. Great jig too! Thank you!

[@k9er233]

Always wear a cartridge respirator when cutting or grinding aluminum. The aluminum dust is very toxic. ;-)

[@ScubaDiverMan711]

Thank you

[@jonathansharp5640]

No joke - just ask the original actor that played the tin man in wizard of oz

[@rollandelliott]

Alloy of aluminum is also VERY important, do NOT try to router 3003 (diamond plate and some sheet metal) because it will gum up your bits. a little bit of water based lubricant will help, but for best results use 5052 or 6063 aluminum alloy. 6061 is the easiest to machine.

[@ChallengeTheNarrative]

I've always got water based lube to hand 😏

[@PoppysGuitar]

@@ChallengeTheNarrative which one is aircraft duraluminum? What number?

[@goodairin]

Interesting and very helpful. Now, I will use my router on a piece of aluminum. Thanks for a great video!

[@chrisflux57]

Finally! Thank you 🙏 This is gold dust. Handheld router cutting aluminium vids/information on internet is nowhere to be seen. Thanks very much 👌🏻👌🏻👌🏻

[@levicamacho7490]

For a small guy starting doing signs this video may help. Wish I could have a CNC machine but can't afford it now. Good to know a manual router can cut aluminum.

[@mudsh4rk]

Aluminum's a really sticky metal, I find spraying a little cutting fluid onto any tool I use to work it (other than files) makes a huge difference. Way less stress on cutting edges, less heat, and cleaning the bit or tool afterward is a lot easier. With hand tapping threads into thicker pieces of aluminum, the cutting fluid can make the difference between being as easy as drilling into pine vs. having the tap potentially get jammed into the work piece (or even snap).

[@robbie6625]

Having worked as a CNC lathe guy.. I can't agree more. I hated working with aluminum. up until that point in my life, I'd never thought a metal could be "sticky"

[@mafatdandebbvlog7127]

Ooooooooooo{ooooo{oooooo{oo

[@mafatdandebbvlog7127]

Jjjjjjjjjjjjjjjjjjjjjjjj=jjj

[@jeremyhay1777]

He's not wrecking it cause it's only a 3/32 cut I suppose but I do agree all aluminum/non ferrous work should have lube

[@revolution3797]

Yep did everything you said,till my bit fell out n went through all the way in one place of the metal. Put it back in tightened it up tighter then lowered it like you said then the bit broke. Man I was upset, I still got to ez out the stuck peace of bit. I ordered a metal cutting one. It must have fractured the bit when it fell out the first time.

[@dennisgarber]

Did the metal one work better? I wonder how many rpm, amp router, thickness of jig. Also, I assume the offset should be 3/32-meaning the jig needs to be 3/32 smaller than the desired pattern all around, if carving outside of the jig: 3/32 bigger, if carving inside the jig.

[@bsmooth5487]

Assembly instructions were a little unclear for a couple of items. It works great kzbin.infoUgkxyFZUPFEey-PuqsPMxqaykBhgA1LWxFHh though, easy to set up and use. If the instructions were better I would have given it 5 stars.

[@JoeOfAllTrades100]

Great video, as a woodworker I'd be reluctant to put a router bit into metal, but your technique is one that may well come in very handy some day. Thanks!

[@inactive67]

You can use your miter and table saw too. When I need repeatable cuts in aluminum it works great, my track saw gets to taste aluminum from time to time too.

[@wb_finewoodworking]

This is a video that will certainly come in handy. Thanks.

[@stevenquan]

First video of yours I have seen. Very nice and clean presentation! You are informative and professional without sounding rehearsed. Thanks for the info, I will definitely subscribe for more.

[@peachtrees27]

Great video to boost my confidence in routing soft metals (I was kinda hesitant prior to this)... big thanks.

[@paultrimble9390]

Yes Sir that's great idea , especially on circle ⭕ 2 thumbs 👍🏻👍🏻.

[@rollandelliott]

Lastly a SINGLE flute upcut bit is better. ONe can cut up to 3/32 aluminum in a single pass because the chips are bigger. a 4mm bit works very well. 6mm will work too, but you are removing more metal so it will slow you down.

[@fightington]

Oh the possibilities!!! Perfect editing mate!!!

[@VigilanteMind]

This has actually helped out alot.

[@brighambaker3381]

Excellent setup of the piece!

[@NathanTilesTheWorld]

This man is in a league of his own.

[@cloudhop]

If only every “how too” video was a good as this !

[@VictorZucchini]

Cheers man.

[@Gidjoiner]

I like that,👍 joiner for 34yrs n still love router jigs, in fact i like them more now that i have the experience to make the router a very useful tool, 😉 providing the jig is correct to begin with 😂

[@flyurway]

I cut similar gauge aluminum (old street signs!) on my table saw or RAS saw all the time using carbide blades. Cuts like butter, just wear earmuffs because it's usually pretty loud.

[@leeloxleigh1471]

Thank you for your video, it was very useful and inspiring on how a router can be used in different ways. I have now subscribed to your channel. 🇬🇧

[@MrAllinwonder]

Thanx for this very well done video. I do some woodworking and a lot of PC case mods. Now I'm ready to try router cutouts in aluminum cases. Dremels and hacksaws and filing always left nasty unprofessional edges.

[@GARDENER42]

Hmm. I'm working on an aluminium, zero clearance insert for my table saw & was going to take the blank plate to a local engineer to have the underside milled to fit the flange in the cast iron table. I have a couple of spiral upcut carbide bits, so might give it a try myself (I have lots of 5mm aluminium sheet to play with...)

[@timstewart6657]

Great video, thank you!

[@Helixan]

That was sick. Thanks for the vid.

[@michaelrobinson9643]

A bit slot to comment but this is worthy of note - nice precise setup and outcome :). What bit would you suggest for doing shallow routing in aluminium plate - eg creating a random shaped segment deep enough to sit some gears in and glue/fill with resin as a steampunk theme.

[@inactive67]

You might want to do an aluminum frame over a plate

[@rachelpanth5527]

Amazing video!

[@memejeff]

Great stuff.

[@douglasaitken3203]

Wow just foud your tutorial video thanks, i am a ex kitchen fitter going to do this with some motorcycle brake caliper mounts 🇬🇧👍

[@mrkrause3]

Thank for sharing!

[@tachizha]

Very helpful video thanks for sharing.

[@vincentbarkley9121]

Well done.

[@MArk-yn4sp]

Great video, thank you.

[@peterbonnell4775]

Well Done!

[@puits-de-science]

I think you don't need to make shallow cuts like these. For thin aluminium like this you can cut in one go. The rpm of the router must not be too high and, very important, check the cutting direction

[@ridhwaanpietersen9076]

Thanks for a great video

[@tykellerman6384]

Thanks Chris good video

[@nationwideofficial7201]

Good Idea

[@bearsrodshop7067]

Really great tip Cris, you should tag this video on Emmas Spare Room work shop for #roughcut2022 coming up on October 1st 2022. I fill your showing using a router to cut thin alum would be a hit. Bear, new subscriber.

[@SimopsAus]

This is similar to using a CNC Router.....I use one to cut aluminium quite often.....instead of the sandwich clamp and double sided tape I use suction. But the principle is the same. For intricate design and work a router (or even better laser) will always give you superior and repetitive results over a “jigsaw”, either wise you’d have CNC jigsaws😜.

[@sandymclea]

Not CNC , HNC. Great idea. Have to try this on a square tube.. can't hold the cut out. A y ideas.

[@evanantin]

You da man, Chris! Thank you :)

[@tommyt4228]

Great video! What's your RPM set to?

[@jonnorris7564]

Clever lad

[@umeshpatel3923]

Amazing idea. Thanks u.

[@markcampbell7710]

THANK YOU GREAT TO KNOW

[@Oakydokes]

What bit would I use to make a copy of another piece that's made of aluminum? Straight bit with a bearing or is there one like you used here made with a bearing?

[@ohnobo14]

I want to create a plate that basically is shaped like a X with the ends having a little room for drill holes and a small bracket. I don’t have all the fancy gear though.

[@desireerajoo9375]

Please can you advise on the best tips for routing steel

[@edrianloisarborilla4602]

What kind of bit did you use? Is it working with metal sheet also? Like 0.5mm to 2mm?

[@adrianperalta7192]

👍tecnica excelente!

[@21thTek]

Excelente !!

[@kldzk]

nice i would go with vaccum for middle part

[@kevinlong1959]

thanks a million!*~

[@valerianpantsulia1730]

Thank you, it was very interesting.///////////

[@rw9495]

I was curious if I could use this same method to make a more complex shape, like the back contour of a guitar neck. If anyone knows please respond!

[@nevetslleksah]

I don’t see why not. You just need to build the template jig if that is the method you would use to route out the shape.

[@mball6433]

Could this cut a 1/4th thick piece of dibond? If not, what would you recommend? I'd prefer a hand tool as I have to cut curved lines. Thank you!

[@v35james78]

Your tooling would take me a month.

[@dennisgarber]

What is the offset?... If I use a 7/16 th inch offset, I would make my jig a half inch shy on all edges? Then an inch small on say a complex jig shape cutting around it?

[@GaryTaylorvw]

Hello, I want to make my own sign, I was given a makita 3612 1/2 inch, what bit do you recommend for cutting aluminium? Is it possible to cut stainless steel too? I’ve got to learn how to set up and use it first but always want to work with them

[@83RBurke]

Would the result be the same on 1/4” thickness?

[@edgarshoe]

Can this method be used for flush cutting as well? Can it be applied to a thin stainless steel sheet?

[@amjadhani8929]

Great video! I'm curious whether you've tried this on steel as well?

[@guitarchitectural]

that would most definitely NOT work, you need a mill to work with steel

[@DiscoverRajivVlogs]

You can cut most aluminums even with iron tools.

[@XaeroR35]

I need to cut a slot in some 80/20 extrusion. Think this will work?

[@hermesex]

My mom asks why I’m bowing to a KZbin video.....

[@construccionesdeobra2323]

Hola, a cuantas RPM se mueve el motor para cortes en aluminio?

[@vw_mods_4711]

You recon it would cut mild steal 1mm thick ???

[@dennisgarber]

Too many questions are not addressed: Will metal bit work better? Brand of bit? I wonder how many rpm, amp router, thickness of jig. Also, I assume the offset should be 3/32-meaning the jig needs to be 3/32 smaller than the desired pattern all around, if carving outside of the jig: 3/32 bigger, if carving inside the jig.

[@denv5221]

👍

[@dschlic1able]

What spindle speed are you using?

[@scottwillis5434]

There are RPM calculators for machining the various metals. Search for "spindle speed for milling aluminum" or similar.

[@patmat.]

Set the router speed to its minimum

[@tecnoprofet]

Router rotation per minute for aluminum application please ? Thanks

[@63Ducati1]

see reply to @gismoguyar (above) Cutting speed is between 500 - 600 fpm for wrought aluminum and 600 - 700 fpm for cast aluminum.

[@brenthawkins204]

What about extruded sheet aluminium

[@M.T....]

how do you deal with the expansion of aluminum as you cut?

[@roberpillott]

Heat expansion? A sharp and good quality bit, very secure work piece, correct RPM and little slow passes like he did, would not generate much heat at all. You should be able to touch the work piece right away without burning your hand.

[@BananaBoy_420]

What's the best way to avoid the metal shavings sticking to your clothes?

[@rollandelliott]

Jig is total overkill. essentraspecialty tapes sells removable double sided tape, just use ONE top jig and tape it to the aluminum.

[@naralas4737]

Jesus, the jig you used to make that cut would cost like $50 to put together. If you did this more than once you'd do well to consider a CNC

[@kenneth6731]

Clean then treat your bits and bearings with Militec-1. You'll thank me later.

[@tommygossett]

Great video. But couldn't you build the jig much easier and with less work if you simply use 4 pcs. of wood put together like a picture frame? And, from my experience, if I were only building one of these, I could just as easily make the jig for a jigsaw and cut it out in one pass.

[@MrAjjordan]

But you have to route the jig right.lol

[@kwzon]

3/32 inches... or about 2 mm. Love the jig, but get on the metric train already.

[@INCC74656I]

so thats 1/8", what about 1" or 1.5"?

[@gizmoguyar]

As long as you do it in shallow passes (1/32 to 1/16 inch per cut) It's totally fine. Definitely use a lubricant, and run your router on the slowest RPM possible (3000 - 5000 K would be ideal).

[@63Ducati1]

@@gizmoguyar I'm sure you don't mean 5000 "K" rpm which is 5,000,000 rpm. No router will go that fast anyway. Your points about reducing the speed an using lube of some kind are certainly valid, and can't be stressed enough. But my Porter Cable 890 router will not go slower than 10,000 rpm, so I have to set my speed to that lowest value and call it good, and use only a small diameter bit. The slowest speed on my Bosch Colt trim router is 16000 rpm, so I can't use it with a bit larger than about 1/8" diameter. The real numbers for aluminum is 500-600 fpm (feet per min) for wrought aluminum (i.e. 5000, 6000 or 7000 etc. series) and 600-700 fpm for cast aluminum (300.x, 400.x, 500.x, 700.x etc series). For a 1/4" router bit, these cutting speeds translate to approximately 7600, 9200 and 10700 rpm for 500, 600, and 700 fpm respectively. Speed for larger diameter bits need to be reduced even further.

[@63Ducati1]

Oops! My bad! I was using the high speed steel bit cutting speeds above. When using carbide bits, the cutting speed for both wrought and cast aluminum is 2820 fpm, which translates to slightly over 43000 rpm for a 1/4" router bit. It is quite possible that Chris knew this when presenting, making it OK to use the maximum speed for cutting aluminum, especially when using a bit 1/4" or smaller, as he did. On the other hand, working backwards using 10000 rpm (the slowest on my PC router) to get over 2820 fpm I would need to use a cutter larger than 1" diameter. ?? I have double-checked my numbers and a Ø1" bit at 2820 fpm is 10,772 rpm. That just doesn't feel right. I'm going to go minumum speed and us nothing larger than Ø1/2" carbide bit. I intend to check this out in my shop this afternoon. I'll reply again after some testing.

[@scor440]

Nice job…..aluminum is not metal just like gasoline engines are not motors they are engines motors are electric.

[@SuperYtviewer]

GTK

[@thomaslogan8857]

i hated that

[@rolandkuhn9066]

Is it possible, yes. Is that process practical, not for me. In a fraction of the time it took for you to set up and complete that cutout, I can easily use a jigsaw and file to complete that same cut with equal results with the same accuracy. Thanks but I prefer what I consider a quicker and safer operation in this case.

[@AlergicToSnow]

Roland Kuhn what’s not safe? I sincerely doubt you can easily get such a straight line with a jigsaw and file. I’ve tried it. Not nearly as easy as you suggest and I’ve been woodworking for a very long time.

[@general4str]

also, that may be faster for you when making one, but if you're making multiple the router and template is the way to go. as long as you are wearing proper ppe and everything is clamped down this is perfectly safe. Just go slow and do shallow passes like the video shows.

[@rolandkuhn9066]

AlergicToSnow re read the reply! I never said it was unsafe so stop saying what I said without reading and pre judging. I said I can and have many times made similar work more simply and quicker. I to have a lot of experience. I have been a carpenter and woodworker for over 30 years. Want me to prove I am just as effective, put your money where your mouth is.

[@AlergicToSnow]

Roland Kuhn you said “quicker and safer”. Looking forward to your video with a jigsaw and file. I don’t know if you can be faster on the first one or not, but I’m pretty sure the second and third are much quicker with the router and jig.

[@TheLizardOfOz]

You did say the jigsaw was safer, so perhaps you should smooth your ruffled feathers. AlergicToSnow asked a legitimate question.

[@roundoval9991]

Excellent video, thank you!

[@21thTek]

Excelente !