How do you cut the aluminum after door holes are in place?

[John6012]

I just realized that I should have waited to cut out the doors until after the aluminum sides were on. I have those holes there and if I glue on the aluminum, it might be somewhat scary since there is more chances to ruin the whole thing if I make a mistake. This is my plan, after the sides are in place, use a box knife and run around the edges of the door opening until I cut thru the thin aluminum. I realize that I can't be too aggressive as it will stretch the aluminum. What do you think? Is this a viable solution? Thanks

[randy chesnutt]

if i understand you. that you need to trim off the excess aluim. around the inside of the door. if that is the case use a router with a straight flute bit with a bearing on the end. that what i used and i put some 3m oil on the bit on and off during cut. sometime the alum. will build up on the bit. you have to clean it off. no big deal.

[Michael W]

There was a thread on this topic just last month. Here is a link:

http://www.mikenchell.com/forums/viewtopic.php?p=45797&highlight=#45797

[jay]

"use an upcut spiral bit..."

[John6012]

Thanks, that makes sense. I think you mean drill or create a hole in the skin and push the bit up thru the skin and into the chuck of the router and then the bearing follows the bit around the door. Right?

[jay]

well, if you use a "self piloting upward cut spiral bit" it will already have a point - but it wouldn't hurt to dril a hole to get it going. most ball bearing cutters are used to trim stock; situations where the entire bit is not surrounded by material. any good woodworking store or webpage should be able to offer a few different choices.

[Kevin A]

There was a recent thread that mentioned using a carbide knife to trim aluminum, this method might work for you especially if you intend to save the the excess for skinning your doors.

[rooster]

I got inside the tear and drilled 3/32" holes in each corner and on the radius and cut it out with my jig saw with a fine tooth upcut blade tilting the saw to follow the outside edge to keep from cutting in to the wall. It worked perfect. I put duct tape on the shoe of the saw to keep from scratching the painted surface. That worked for me.

Jim,

[Geron]

One other option. If you have access to an air compressor and "nibbler" This combo works like a charm no matter if your cutting out the complete door or trimming the edge. Eliminates router all but for a small amount of clean up in some areas.

geron