the best tools to use to work on aluminum?

Sorry if this is in the wrong forum, but wasnt sure where to put it, but this is my first time to try to fabricate parts for my truck, and i was wondering what tools are best to use on aluminum to counter sink the screws and to drill slots in so you can adjust the plate either this way or that? thanks for anyhelp as you can guess i'm sorta clueless to this and have no idea where to even start.

[bdebde]

I use hack saw, drill bits, files, and a countersink bit

[MetalMan]

Like bdebde said, countersink bit to make countersunk holes. I use 1/4" for 3mm screws and 3/8" for 4mm screws, and adjust the depth to make sure the screw heads aren't above the surface.

To make slots, I use a drill bit to make the inital hole, and then a scroll saw to cut out the slot.

maybe my local hardware store just doesnt have it, but i couldnt find a countersink bit, that what i was curiuos if they actuallyhad one or ppl were just using something else to do the countersink. thanks guys for the help

[BrianG]

I use this for countersinking.

For slots, I drill a hole on both ends of the slot. I then use this type of bit on a dremel tool. Then, just cut away.

For cutting, I use a hacksaw and/or Dremel tool with cutting wheels (wear goggles!). If thinner than ~2mm, I use a nibbling tool to make nice square cuts and files/Dremel sanding wheel to clean up the edges.

thanks brian for the post, though its a bit late, damn moving and getting the internet back

[Serum]

I use M3, M4 taps, scroll saw, rasps (different grades), dremel, drills, scotch brite/waterproof sanding paper, calipers, ruler and some patience.

Easiest thing to do is to draw something, and print it 1:1; that way you can simple put the 'template' on the aluminum with double sided tape and cut away the stuff that's in the way.

A vice is a handy tool too. As is a press drill, but you can manage without both.

you are able to make parts like this fair easy;

Originally Posted by Serum

I use M3, M4 taps, scroll saw, rasps (different grades), dremel, drills, scotch brite/waterproof sanding paper, calipers, ruler and some patience.

Easiest thing to do is to draw something, and print it 1:1; that way you can simple put the 'template' on the aluminum with double sided tape and cut away the stuff that's in the way.

A vice is a handy tool too. As is a press drill, but you can manage without both.

you are able to make parts like this fair easy;

Thats just showing off Serum

Thats amassing!

I need some tools so I can work with alu

[MetalMan]

Originally Posted by Serum

I use M3, M4 taps, scroll saw, rasps (different grades), dremel, drills, scotch brite/waterproof sanding paper, calipers, ruler and some patience.

Easiest thing to do is to draw something, and print it 1:1; that way you can simple put the 'template' on the aluminum with double sided tape and cut away the stuff that's in the way.

A vice is a handy tool too. As is a press drill, but you can manage without both.

you are able to make parts like this fair easy;

Seems like we both make our parts very similarly (print out drawing and double-sided tape it to the material, cut with scroll saw). Except you definitely take more time on yours, getting the edges nicer. I don't finish my parts like that...
You didn't cut that CF with the scroll saw, did you? I haven't had a blade last more than 30sec. on any composite fiber materials (fiberglass, CF, G10, etc).

[Serum]

NO man.. that wasn't my intention.. Just consider what you can make without too expensive tools

That's not showing off, i don't consider myself good at it. Considering the used tools, it's okay though,



this was 10mm thick aluminum, a lot harder to work on. made the x-brace and the holder for the schulze the same way.

Im just giving you a hard time

Your VERY good at it, dont tell us you arent lol, those mounts look VERY professional..... It looks like it was machined, and then you sanded it or something

Its perfect (IMO)!!

[Serum]

Thanks, but i think its more a matter of patience than anything else!

[Promod]

Nice work Serum!! Your stuff always looks Professional! Glad to know you use simple tools to make such nice thinks. Looks like I need to work on my fabrication skills.


Promod

[JERRY2KONE]

Yeah nice work Serum. It is a nice talent when you need something fabricated and there is not already something available or $$$ reasonable enough to do the job. Then you are able to fabricate it with your own two hands (& some tools). Thats cool. That is something that I think a lot of guys would like to have the confidence to do. Some things can be learned at reasonable sacrifices. Some things are just God given talents and we need to use them to our advantage.

[Serum]

No, i cut that carbon with a cutting wheel and the dremel.