making a router jig

[North Shore Fab]

i have a 3''x12'' piece of delron 3/4'' thick, i had never routed something that thick and didnt think i couldnt do it. my router bit only has a 1/2/ of cutting surface. i need to have these things done by tomorrow. the only options i see are

have the bit ground so it can cut down that far before it gets into the taper of the shank

find a different bit our an endmill and make an adapter

make a jig that i can cut the top side with some holes in it for pins and then flip it and cut the other half. this seems the most time consuming and i know it has been done with a radiator cap at TM and i think pyrogeek did something like this.

im really not wanting to do that last option but would be the only thing i can do with what i already have. any ideas on how to make a jig for that or pictures of one.

[sgalway]

Your router bit flutes are smaller in diameter than the shank? For delrin I would get a bigger router bit (flutes are slightly larger in diameter than the shank), there is small cutting load if you step into the material 1/8" or so at a time and manage your spindle/travel speed ratio. Local hardware store should have a suitable router bit.

[stealthshooter]

If your in a pinch go to your local hardware store and pick up a rotozip bit. They have a very long length of cut. You will have to slow the feed down so you don't break it. If your lucky enough to live in a town with a lowest or home depot they sell 1/4" spiral router bits that are have a really long LOC also.

[stealthshooter]

Choices from Lowes and Home depot. My local hardware stores don't carry these so I have a pretty good stock of bits in case I break one.

http://www.lowes.com/pd_57163-353-85...3D1&facetInfo=

http://www.homedepot.com/h_d1/N-5yc1...&storeId=10051

http://www.homedepot.com/h_d1/N-25ec...&storeId=10051

[North Shore Fab]

thanks for the tips, after posting that i went to my machinst to see what he could do. i told him to make an adapter for some endmills i found. he was going to make a split ring collar and a 1/4 to 3/16 adapter. also had him grind down the 1/8 router bit i had. going to pic up what he made and get to work ill post pics later.

i think after this im telling people no more router work till i built a separate cnc machine just for it. setting up my router setup on an 8x10 water table to route a 3''x12'' piece of delron is less then ideal

[PARANOID56]

all i do is plastic. get a 1/4" streight bit and go to town. i use it for 1" plastic all the time, i step down 1/8" at a time till its though.

[North Shore Fab]

only reason i am using such a small bit is the size of the holes. number 10 hole. i got the parts cut the little adapter the machinst made came out pretty sweet ill have pics up later

[PARANOID56]

you could try doing a tool change. never tried it myself as lucklly the smallest hole is 1/4" i did try some 1/8" ones but like you said you can only cut those so deep.

[stealthshooter]

Glad it worked out for you. Here are the endmills and router bits I have managed to gather the last couple months.

[Laynez71]

I know youve already taken care of this but heres a tip for future projects.

Check out Onsrud for CNC router bits. I run a big CNC router for a living and have had great success with their tools, for thick delron or any other high wear plastic I would look into the 63-776 series tool, its 1/4" diameter and has a 1.25" cutter length.

http://www.carbidespecialties.com/On...l_O-Flutes.htm

[pyrogeek]

X2. 9 out 10 of my bits are onsrud and they have speed and feed charts.