So what do I need to know for removing material from my booger welds? I presume that small teeth will load up, is there a specific type for aluminum?
I assume I'd use the same stuff for the initial stages of porting then finish with sandpaper on a dowel or something?
Working aluminum, the first tool you need is hearing protection. The second tool is eye protection.
There are al. specific bits for milling machined and routers, but I'd just use a flappy disc.
Flappy disc won't work as I need to get into a crevice.
Yep, I'd use an abrasive and not a cutting tool. Aluminum abrades quickly and also clogs up cutting tools quickly.
for the crevice, use a burr shaped to your needs, as big as you can stand because cutting edge speed is life. And a tip a head porter taught me: Use gear oil for cutting lube. It's amazing.
Die grinder with a bit suited to aluminum. Keep it lubed so it does not clog.
For finishing work a "finger sander" comes in handy when working in tight places.
In reply to NOHOME :
Not the Harbor Freight one, unless you are a fan of frustration.
I use one off the Matco truck at work. (might be Matco, might be Silver Eagle). The roller on the end is shaped like the roller on an English wheel, which keeps the belt centered, and it has pads on both sides to be able to sand against. Two things the HF unit lacks.
Single Cut Carbide burrs, files, wood cutting tools and flap discs for aluminum.
Deck it on a mill for the flange and hg surfaces. Carbide burr for the insides where the finish isn't as important.
When using a carbide burr, WD-40 is a decent lubricant and helps prevent clogging. Picking aluminum out of the burr got real old, real fast. Take your time, light pressure, lower speed- don't melt the aluminum since that also leads to sticking.
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