What tool am I going to have to purchase that I can cleanly cut the extruded aluminum to build my router? I get a bit discouraged looking around the net when up keeps popping 200+ dollar chop saws and 500 dollar miter saws requiring an additional 60 dollar blade. At that rate I might as well buy a Chinese machine and work with it which I really do not want to do. My last hold off to starting the project is this part of the equation then I am going to intermix Routy and Ox.
You could always check locally for rental equipment or check to see if you have a local hackerspace where you could cut it. Ultimately however, Brian's suggestion may be the best low cost option.
I cut mine by hand and with no miter box. Time consuming but not as half-bad as I initially envisioned. The miter box is certainly a great idea. I also planned my machine so that I would need the minimal number of cuts (using the one meter extrusions as side). Only a word of caution, the extrusions might have some tolerance and might not all be of the same length.
Yes, I was thinking about the miter box and a 32T blade for the hack saw. I know I need that box as I have never been able to cut straight with a hacksaw. I forgot to add this question but will the 20x80 fit so it is laying down horizontally to cut?
If you get a box that can handle a standard 2x4 you shouldn't have any problem with the 80mm which is just a smidge over 3 1/8"
Aye, with modern 2x4 boards being 2.5 x 3.5. Perfect, as I have never ever been able to make a straight cut with a hacksaw without guides. By the way do they make a better blade for this than the 32T for a hacksaw? Which brand is good in people's opinion as I use Lenox but getting a 32T Lenox has to be mail ordered here so if I am going to have to MO it I might as well ask if there is better and/or with more teeth and where from too.
Don't forget the cutting/tapping fluid. A couple drops in the cut lets the blade slide real smooth without binding. I've cut plenty of v-slot with the hacksaw. Works fine. I square it up on a belt sander afterwords for clean ends and perfect length.
I was going to buy all of my materials from the Open builds website as I am building a Routy but with the stability of the OX on the frame. Is there another source for V-Rail/V-Slot?
Perfect, I was hoping that would work. Just use the pull stroke, not the push stroke, to cut it and spray it once before and once in the middle of each cut.
I live in the USA so was going to go directly with the source but if the prices are lower and/or they will cut them for me and OB wouldn't I will go with someone else. Any preferences or just grab one?
I saw that at HD and was put off by the thread cutting part. Works really well I take? Any better than WD40?
Yes much better because most people do not know the "WD" stands for water dispersant. It is not a good lubricant. The last part of the part description is "Cutting Oil" and that is what you are doing. The "Thread" part of the name is just it's common usage. Bob
Yep, I personally hate WD as I found much better for many jobs so I never understood why I see people (in videos) spray WD40 on the material as the spindle is cutting.
$120 Ryobi Miter Saw from home depot and $50 Oshlun blade: 10 inch for non ferrous metals with 100 carbide teeth. Cuts like butter. I make all my cuts dry.
"Just use the pull stroke, not the push stroke" Wrong. Never try to cut with the teeth "scraping" on their backside. Always let the saw cut. Don't force it. If you are using any kind of handsaw, then I don't believe that you would need any lubricant of any kind. If you are more comfortable "pulling" a saw rather than "pushing" it, then turn the hacksaw blade around backwards. Done deal. (fwiw - Japanese woodworking saws are designed to be used on the pull stroke.) I cut extrusions, dry, with a DeWalt miter saw with a general purpose carbide blade. No problems other than the small little bits of aluminum sawdust (flakes) flying around. (glasses and earplugs please) If you are budget challenged, (is that politically correct?) then the miter box and hacksaw is at the bottom of the foodchain. If you ever decide to go powered, don't forget about a bandsaw. Small used ones can be had for not so much. Just don't get a 3-wheel. They're a real bear to get and keep the blade tracking. Stick to the 2-wheel variety. Well, that's my 2 cents worth. Back to work.
