Milling Cast Iron using a Woodworking Router

My new table saw has these weird dovetail mitre slots and I really don't want to have to deal with those. And instead of the overcomplicated solution that I had thought of initially, I ended up using my woodworking router.
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[@kenl5217]

Now the warranty is void

[@AlessandroAllegretti]

😂

[@even7steven]

lmaoshifottaasalotf!!

[@MrAdamdumont89]

pretty sure the warranty expired decades ago lol

[@Jeremy_Fielding]

I don't think I would have tried that... Now I definitely have to try that. Given the same conditions of course. What a great simple solution.

[@EnlightenedSavage]

Jeremy Fielding i think iwould have made matching dove tails ... not super easy but not too hard either

[@tlaim]

Love ur vids jeremy

[@Jer_Schmidt]

Nice, the cut looks surprisingly clean! And so do your socks!

[@OneManBandWoodworks]

Great socks, thanks for sharing.

[@TheLaudi]

Alle sagten das geht nicht, doch dann kam einer, der wusste das nicht und hat's gemacht. Ein beeindruckend gutes Ergebnis! Ich bin baff!

[@smagnut]

Pushstick meltingpot... priceless 👍😎

[@michaelcoceski5442]

I noticed (and liked) your socks and your 'safety boots' before you even mentioned them. Special credit for having the courage to wear those on camera. Subscribed.

[@SAHBfan]

I have a problem with my table saw mitre slot, too. Too narrow in my case and not a standard size. This is exactly the video I needed! Excellent work, thank you.

[@BrassLock]

I was gobsmacked 👟. The idea of using a woodworker's router-bit to mill cast iron was a bit awe inspiring as well.

[@PhilVandelay]

Wow, I would not have expected this to work. Then again, ever since you cut steel with a handheld circular saw this shouldn't be surprising. Love the "whatever works" approach.

[@dasstackenblochen9250]

Well to be fair he did use a dry-cut blade and an speed-controlled saw which can do this (part-time); it wasn't a blade for wood ;)

[@glennfelpel9785]

Congratulations, Vere well done. Never considered cutting Cast Iron with a router bit, always something new to learn. And surely like the idea that you really didn't spoil the slot for its initial intended use. Thank you for sharing.

[@jdniedner]

Great push stick reference!

[@Wordsnwood]

Amazing socks. And I learned something about routers too. Great job!

[@jack13210]

I had the same issue on my old LUREM 260 CSI and after using Comas' trick , I can no use "standard" cutting jigs! Excellent very easy to do! ..... and do not forget your safety glasses!!!

[@BossSpringsteen69]

Literally, the only video that i've seen that talks about cutting a tablesaw top.

[@holzhandwerk_ak]

Excellent socks, and a great idea. Thanks for sharing!

[@austinsteele7513]

Exactly the video I have been looking for!! Awesome work too😎

[@Tjita1]

I did not think that would work, especially not with a wood working bit.. I'm impressed.

[@keiththrelkeld5890]

And I thought that I had a pair! LOL fascinated that it worked so well. I'm an old dog, and this.......well you, know, new trick!

[@blickberg8404]

That's a very nice table saw. Looking forward to your next projects.

[@patcostelloe8268]

Wonderful job

[@artconnolly9519]

Very cool video and even cooler table saw. She's a beast I love it.

[@Dingbat217]

Awesome! When I first read the title of the video I was thinking 'Is he nuts?' but thinking about it that should indeed work well as the tungsten carbide used in router bits is way harder than cast iron so as long as you work slowly with shallow passes it should cut just fine, which is exactly what it turned out to do! Thanks for sharing it! :-)

[@klschofield71]

You got some balls Cosmas...when you let go to switch on your dust collector I thought for sure something bad was going to happen...I'm pleasantly disappointed. Keep up the great vijeos.

[@mikkelasmussen7555]

That is one beautiful tablesaw. Love your work. Keep it up.

[@grumblycurmudgeon]

Interesting indeed! The challenge there isn't cutting the iron. Iron cuts surprisingly easily (assuming it's not white iron). The hard part is cu- well, milling really, for that's precisely what you did - the challenge is _milling_ a dead straight line suitable for use as a miter slot. But you did brilliantly, mate! As with everything involved in making, the devil is in the details. Preparation is key. And you very wisely took all the guess work out of the operation. Very, very nice work!

[@zohranbloedjes9770]

Whel that was something I didn't expected

[@g81atherton]

Idk Cosmas, I think there's really only room for one kind of pushstick in every shop. The other pushstick should assimilate, or go back to John Heisz's shop.

[@labrat7357]

I don't know about your socks but I do have the hots for your table saw, that is one beautiful unit. All the best.

[@lemagreengreen]

Great video. I have to admit I was feeling a pucker factor of about ten when you first started but then as you say - it's just cast iron. Something quite unnerving about using woodworking tools on metal though :)

[@TeknixTrix]

*Holding my breath waiting for the snag/explosion* whew!

[@TheeModerateGamer]

Did anyone else rewind just to see his socks ?!? Ahaha

[@chk50]

Didnˋt need to. I was flashed when they showed up.

[@gregkieser1157]

Very interesting. Nice video. Reasonable socks.....lousy push stick!

[@Franksshed]

Richtig... geile... Socken! Bitte amazonlink nachreichen, die muss ich haben 👍 Das Video wie immer interessant!

[@Psychlist1972]

Nice saw and nice mod.

[@spock6692]

This is absolutely brilliant! Russians would call this a "russian" solution (because it is cheap, efficient and "against the rules") . The reason is - most of them have never traveled abroad!!! :) Thank you for sharing!!! Me, a russian, will know that this way is possible! ;)

[@AlessandroAllegretti]

I'm sure if I try this, I'll catch fire 😂 You 've done a nice job! A brave alternative to a good dedicated elicoidal bit (more expensive solution) 😉

[@mihaipopescu5304]

Those are not socks those are protective equipment ;)) enforced with the rubber slippers for a better protection of your toes;)) . I wonder if it will work also on aluminium ?

[@Flif0]

Niccce! well done! i may use that info to fix my table saw...

[@eeThial5]

Wow, what a great idea!

[@tom7601]

Well done, sir!

[@youmbgtube]

I know this is old but glad I found it. I have a nice 1950 Delta Unisaw that my son and I completely refurbished several years ago. What has always bothered me is there is no "T" slot (it is straight sided). Wonder if I could use a similar method to add this? - Thanks

[@lewisway6811]

An An end mill, I think would have been a better bit choice.

[@turningpoint6643]

I doubt a proper carbide end mill would have made much or maybe any difference since the cutting speeds were well above the recommendations for even very rigid mills machining cast iron never mind a router with non precision bearings and hand moved for the feed. Far more money for an end mill with probably a one time use and ruining the cutting edge on the router bit for fine woodworking was the cheapest method if you don't know for sure it will work. I would have chosen the smallest diameter router bit I could find just to lower the cutting speed for it's diameter. Then again I would have just milled it since I've got the equipment to do so. Routers do ok on aluminum and maybe the softer alloys of brass, but that's as much as I'd try one with. Yes it worked and I guess that's what counts. But there's far better methods.

[@hisatnam]

Thanks I was looking for that.

[@silatty4313]

Nice work Cosmas. Good results, although I'd have just used an epoxy with a bar to form the material.

[@derwissenskiosk8041]

Ich hätte nicht gedacht (Niemals), das ein Holzfräser mit HM Bestückung Gusseisen fräsen kann.... Ich weis das es mit Aluminium geht aber das sind Welten... :D

Der Wissenskiosk Nicht wirklich

[@Exgrmbl]

Messing kann man damit auch fräsen. Das Problem ist nicht wirklich das Material der Schneide sondern das zwei Schneiden in der Regel zu wenig sind um das Ding kontrolliert und sicher führen zu können.

[@RealJoschi]

The socks complement your safety boots! ;)

[@claudioae1743]

Very Very Very good

[@krrrruptidsoless]

I got to mill my miter slots one, 2 mils deeper and one 1 mil deeper because I just bought a new miter gauge that sticks above the slots.... I don't know this is going to turn out if I ever find a bit I don't know why one side would be deeper than the other either...🤷 I guess that's how old school did it...🥴

[@michael.schuler]

Thanks for posting! What rpm was the router turning? How much did you remove on the final (deepest) pass? Looks like that final pass might have been 0.5mm wide x 3mm high. Is that about right?

[@bretlambky]

Good job, very risky! Nice table saw as well you don’t find saws like readily available here in my part of the world..

[@mrgodBG]

you are next matthias wandel GJ

[@thenorwegianmaker]

Argh.... Now I have to watch it again!

[@thenorwegianmaker]

Yes, my kind of socks!

[@colmone5592]

Nice job.

[@DR-br5gb]

Very cool

[@sunc93]

Krass... hätte nicht gedacht, dass das funktioniert. 👍🏻 Ich hätte mir vermutlich wenigstens einen Metallfräser gekauft, aber anscheinend ja nicht nötig. Die Säge sieht echt gut aus. Wo bewegt man sich da preislich so ungefähr?

[@Cactusworkshopchannel]

wow this is crazy!

[@Ollaris]

Haha! Die socken! I never thougt you can do this with a woodworking tool! Und was ist mit dem ersten upload passiert? :)

[@travnicek]

Hi Cosmas, really enjoy your videos, and on this one I have two questions. Why didn't you just cut it with that beauty of a converter chop saw at a set depth? Could've been done in minutes for exactly the same results. Unless you were concerned about potential saw marks being left. Other than that... regarding your crocs. Have you ever crushed a toe? Your call of course, but I wanted to mention that even a 2kg aluminium cylinder head from a scuba air compressor I was fixing when living in the Caribbean, was enough to disable me for a couple weeks and something I still feel to this day.

[@jorgenlannock]

yes woodworking router. but a sharp carbide flute rips about anything. i myself would probably have tried it with a anglegrinder on a sturdy sled 😁. but your way works too offcourse.

[@DennisNeijmeijer]

Hey great video. I'm hoping to ask for your input after having this experience. Do you think it's possible to cut the miter slot deeper using this method? I really want to insert a aluminum T track in my own older cast iron top. But I'm seriously doubtful about cutting into the material. I have connections in the metal industrie and for more money I can have it done professionally... Would you do it yourself? Or would you pay for a business to do it, if you had to cut like 6mm into the solid top.

[@vileguile4]

Can you melt and mold some kind of plastic in those slots? Maybe not related to this video. ... Thanks for upload!

[@ldwithrow08]

It would probably be best if you had a variable speed router and slowed it down a bit. I have always wanted to re-machine my Craftsman table saw miter slots to a T shape at the bottom, like so-called "commercial" saws, but can't find an appropriate cutter.

[@CosmasBauer]

It is a variable speed router and I slowed it down as much as possible. A fixed speed router would destroy that bit.

[@tomashancil7805]

Cosmas, could you please identify the type of the saw? it looks really good. Make and model please.

[@lioncrunch]

Genius

[@juanrivero8]

I think you used a carbide bit. Had you used anything else, it would ruin the bit for sure and probably the slot as well. A router runs much too fast for cast iron.

[@johnthompson3462]

very interesting and educational.I am curious as to ...where you are - country - and what brand of saw you have.And, why it has only one mitre slot

[@MegaSerif]

Hi Cosmas, I am really inspired , what brand/type is your new saw ? did you buy it or it was a gift ?

[@wilhelm826]

... Hersteller und Typ der Säge würde mich auch interessieren (als frischer Besitzer einer Ulmia 1612, Baujahr 1971)

[@americanwoodworkingtrickss6543]

You could rout it because the top was made of cast iron. Not even try this with steel counter top.

[@CosmasBauer]

Eh yeah, it is indeed cast iron. And that's why I was pretty sure it would work.

[@mildyproductive9726]

I suspect it would still work, it just might have required shallower cuts and more passes. A carbide bur will cut any kind of steel just fine in a die grinder running exactly the same RPM, even freehand. An endmill or carbide router bit would be too grabby without a guide. As long as the guide was used and the cut depth very small, I see no reason it wouldn't work in steel. One could even use a carbide bur to do the bulk of the removal and finish with the endmill/router bit. Most carbide burs will leave little diamond shaped grooves, if you use a rigid guide. But by slowly advancing the depth of the bit some thousandths of an inch at a time, you would end up with a fairly good surface to easily finish.

[@RyabininME]

Вот никогда не понимал за что дизлайкать такие видео? Качество видео отличное, звук супер, сюжет закончен. Не нравится способ которым сделано, ну так много в этом мире делается не так как нам нравится. за что видос то минусовать?

[@andrej.babichev]

Я сначала грешным делом подумал, что он так по чугуну)

[@glennlopez6772]

What bit did you use? Could 1/4 inch slots be cut in brass? Thanks for the video!

[@1873Winchester]

What's the brand of this saw? I got a german saw too (Rapid pk-100), but this one looks a step above that, has the same infurating dovetailed slots. I use the sliding table fence to attach jigs and sleds.

[@jonnywiseman9283]

That's a really good video, thanks for posting. I was going to do the same to my table saw. It's a Scheppach Precisa 4, with a really annoying mitre slot. It's an inverted T shape - 10.5mm at the top opening to 21mm at the bottom. It won't take a standard 19mm mitre bar etc, so bang goes buying an Incra mitre gauge. Can I ask you a question? The first side you routered, did you move your piece of guide sheet back a few mm each pass? then for the other side you just added spacer pieces. I'm going to give it a try and hope the type of cast iron allows me to do this - I'll try a small test in a location that won't bother me if it doesn't work.Thanks againJonny

[@jonnywiseman9283]

Routered my mitre track. Worked a treat. Really easy to cut the cast iron with the wood bit!!! Thanks for posting the video.

[@soosaisteven3984]

Metal machining using wood working tool? Great....!!

[@louiscypher7090]

Damn, how many plies is that router base? Lol.

[@GNU_Linux_for_good]

I have just *one* question left: can the Easter Bunny give away an industrial beast like yours for free? Where did you find that, for what price? 06:30 Sure enough - it was worth the effort! Great job.

[@johanvandyk6532]

Brave man :)

[@brh4015]

AEG: Auspacken, Einstecken, Garantiefall

[@EigenkonstruktDe]

Ok just like "two Girls, one Cup" I didnt want to see it, i saw it and the finish is quite interesting....

[@nilssxrgerx55]

eigenKonstrukt now thats a comment ..

[@stuffoflardohfortheloveof]

I feel sick....can I open my eyes yet?

[@Netsend-Norway]

wow you are tuff ... nice

[@ericbardell496]

what is the make of that saw, its interesting how the sliding table can be folded down out of the way

[@CosmasBauer]

It's a Bäuerle.

[@realjester]

Nice socks👍👍👍

[@EllinonEnosis]

But but but....why not a milling bit ?

[@CosmasBauer]

But but but... why a milling bit?

[@sidgar1]

A milling bit is designed to cut metal. A woodworking router bit? Not so much. But if it worked, it worked, I suppose.

[@MastercraftKARIGAR]

@@sidgar1 a milling bit preferred two flute solid carbide would have saved lot of time.

[@andrewaustin6941]

Cool!

[@CapApollo]

3:20 it socks!

[@normcessler6895]

@Alyson Grassi it works, so no!

[@BudgetBuiltDiesel]

3:00 Nice socks.

[@miki09876]

Cast iron.... Guts

[@foulukun]

Is it a cheap chinese bit or a good one?

[@CosmasBauer]

A good one.

[@Zebra66]

I wonder if this guy is still alive. Seems to have a death-wish

[@stanislavp1903]

at first i thought it`s a joke

[@juleswebb1885]

I love your videos but i have visually far superior socks, in my humble opinion. Are your socks INDUSTRIAL??

[@sacriptex5870]

cosmas do you really need all this precision??

[@CosmasBauer]

Yep.

[@sacriptex5870]

Cosmas Bauer voce gosta de pao?

[@TimothyHall13]

Socks kzbin.info/www/bejne/i6PdZmqIi6hka6Mm20s

[@DonJohn87_YT]

or just 3:20 :P

[@jochenmayer]

Don't like those socks...

[@alysongr]

Cosmas, nice work! But, man...that wasn´t too much RPM for Cast Iron? 30k RPM x 5/8"? And the carbide that you have used is for wood not for steel or metal.