How do I get deep scratches out of my aluminum?

[fornesto]

While trimming the .040 aluminum on the side of my TD with a router, a few bits of aluminum chunk got under the router and put some good scratches in the aluminum. I would really like to get these scratches out. I've no experience with this type of thing. I've heard of using steel wool, polish, buffers. This is a real good scratch (you can feel it). What is the best approach?

P.S. I can't figure out how anyone could trim the aluminum with a router! My attempt was a total failure. I'm now a member of the pro-air sheers team!

[madjack]

...remember, if you trim aluminum with a router, you need a speed control, to slow it down, so that it "cuts" instead of "burning/melting" thru the material
madjack

[fornesto]

I had one. The router cut the aluminum fine, but the little bits got under the router base and scratched the aluminum. I was using a 1/2 hp router. Maybe a beefier router would have yielded better results. If I slowed down too much, the router locked up. If I sped it up, it would melt the aluminum. That and the bits under the router base just frustricated me and I moved onto the air shears.

[mikeschn]

I've not had very good luck routing aluminum either. I ended up cutting it with a jig saw while on the bench...



I did use the speed control, but it didn't help. Either there was not enough torque, or it was running too fast. And I have a Porter Cable router...

I bought the shears for my first Benroy, and it's okay, but barely...

For the generic plans of the Benroy, I am going to suggest a jig saw...

Mike...

[toypusher]

When I cut out my profile, I made a sandwich with the aluminum between the two sides of plywood. I don't know yet how hard it will be to attach the aluminum skin, but it is not scratched and it cut just fine with a jigsaw. I then sanded it (all together still) with my belt sander. I think that I have a couple of pictures somewhere that I will post in my gallery when I get a chance.

Kerry

[fornesto]

When I cut out my profile, I made a sandwich with the aluminum between the two sides of plywood. I don't know yet how hard it will be to attach the aluminum skin, but it is not scratched and it cut just fine with a jigsaw. I then sanded it (all together still) with my belt sander. I think that I have a couple of pictures somewhere that I will post in my gallery when I get a chance.

Kerry

On No. 2 (did I say that?) I will definitely use this approach!

[toypusher]

Found the pics and put them in my gallery

http://www.mikenchell.com/forums/album_personal.php

Kerry

[dguff]

I also used the sandwich technique, cutting both sides and both skins together then finishing with a belt sander. Both sides come out the same and both skins fit without further trimming.

[mikeschn]

On No. 2 (did I say that?) I will definitely use this approach!

Let me know when you start #2, I'll put you into the 2nd teardrop club!!!



Mike...

[Denny Unfried]

...remember, if you trim aluminum with a router, you need a speed control, to slow it down, so that it "cuts" instead of "burning/melting" thru the material
madjack

I slowed my router with a voltage control to 40 volts. Then used my Masonite profile template to sandwich the aluminum against the side and went around it like butter. Just had to keep playing leap frog with the pipe clamps.

Denny

[SteveH]

Fornesto,

I too have the scratches in the side of my trailer from aluminum bits getting under the router.

I've decided to leave them that way because the only way I can figure out to get them out ends up with having to polish the entire trailer. With that in mind, the scratches are not that bad.

[doug hodder]

What I have done before is tape off the path that you want to rout with masking tape, at least the width of the router base on the material that you want to protect. I also have an assistant using the air hose with a blower to remove the chips. The blower needs to be right there near the router. Another trick is to use a collar on the router base, and either an upcut or down cut spiral bit, they don't gall like a laminate trim bit. If you do it this way, you have to have a template laying on the top of the material that you want to rout, a pain to set up exact. It ain't perfect, but I've had good luck using both of these techniques. I also lay the material on top of a sheet of cheap styro insulation. You don't need to worry about the bit cutting into anything else. Just my experience. Doug Hodder