CDie grinder bit for aluminum...

[tkent02]

Which type bits work the best on aluminum???

Cutting the cases with a die grinder to fit the bigger 650 cylinders in, the stones clog up, the steel bits with the little cutting tips just wear out. What works the best?

[OLDENUFF]

If you get a quality bit, it won't plug or wear out. This is the one I used on mine. Stone bits leave undsireable sand everywhere.

[tkent02]

OK, thanks.

[Nessism]

Edit: post above showed up while I was typing...

Carbide burr w/ 1/4" shank for a die grinder. Don't bear down too hard otherwise the aluminum will heat up and clog up the flutes (or cutting faces).

[49er]

Edit: post above showed up while I was typing...

Carbide burr w/ 1/4" shank for a die grinder. Don't bear down too hard otherwise the aluminum will heat up and clog up the flutes (or cutting faces).

Good advice...........also helps if you can control the rpm to the correct speed for ali and the bits diameter. A good quality electric die grinder (Makita as example) will give you 7000-28000 rpm choice.

[Sci85]

I used a bit like Oldenuff posted with my dremel. Worked well but it did take two of them to get the job done.

[Dogma]

Machinists I work with use WD-40 to keep aluminum from clogging grinding wheels and burrs in situations where the piece isn't flooded in coolant. I would think most any kind of fluid you can spray onto the tool and can stick to it at high revs should keep aluminum from mushing into cavities.

If the tool geometry doesn't trap the chips, you can cut aluminum dry. The tool OLDENUFF posted a pic of looks like it should clear chips. At least there is the option to clean that type if you do gum it up. Aluminum casting alloys can have a fair amount of silicon crystals in them, so it's no surprise that tool life could be an issue. Production tools for aluminum use materials approaching diamond in hardness at the cutting edge. Or actual diamond coatings.

[tkent02]

OK, Got a better burr and more WD-Douche and it's done. Thanks.

[GregT]

For future reference, a cake of hand soap is a cleaner way of keeping the bit lubed and unclogged. Just run the bit against the soap occasionally.

[Dogma]

For future reference, a cake of hand soap is a cleaner way of keeping the bit lubed and unclogged. Just run the bit against the soap occasionally.

Cleaner because soap is inherently clean, right?

[GregT]

Cleaner because soap is inherently clean, right?

No - cleaner because you don't finish up having to wipe WD40 off everything on the bench....

[tkent02]

Just tried the soap for a little final grind, it works great.

[Sci85]

You gotta thread going on your build tkent02? I love this conversion. Thinking about doing another one on a spoked 550 this time.

[tkent02]

Yep, but it's going kind of slow, just too many bikes that actually run and need to be ridden.

http://www.thegsresources.com/_forum/showthread.php?t=201784

[Sci85]

Oh yeah. I need to subscribe. Keep it going. I promise you it will be one of your funnest bikes once completed. Light, nimble, and much faster. It's really fun to run around at 9000rpm and hear that sweet scream from the exhaust pipe.