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Ive used a router table to cut aluminum using the guide fence. found that using cutting oil helps keep the bit from clogging. I use a bandsaw, with a drop or two of oil, and file to do major cuts and use router for internal cuts. Im very careful and respect the tool. The pin router essentially works like the bearing on a laminate trim bit but allows for smaller diameter cuts and also less gap between pattern and material being cut so much better for detail work I was wondering if you ccould apply the cutting lube to fiberglass or carbon fiber to help prolong cutting edge and make cut less jumpy. I would think that oil might not be so good as it might penetrate into the fibers as you cut, but maybe a water based lube would work.

I figure i will make a pin router soon and with these writeups I think It should be a little easier. thanks for posting this and love the work.

From.experience, dry cutting composites causes way less mess, and makes tool path issues go away.

I'm already planning out the next version. It's a matter of learning as you go what will work for you. The next version for me will have a CNC router fixture to eliminate the bit of flex I get (it's very minimal, yet amplified when cutting!) and also a better method for setting the arm stop. Probably a longer arm as well

I use a carbide cutter that comes from the pcb industry, they cut like butter.

Good to know about composites. I have yet to play with them and have most experience with plastics, alloy, and steel. A little drop of 3in1 oil on cold rolled steel or alloy will make blades and bits last longer and cut smoother.

ok well over the weekend i made a cutting box for the same purpose as the pin router.. here are a few pics

i decided to go with a Tungsten Carbide trim router bit.. it is 6mm diameter so it should do reasonable internal radius cuts.. bearing is pretty close to the cutter so shouldn't need too thick a double sided tape..

secondly i have also mounted a jigsaw underneath so as i can do quick rough cuts easily.. figured i will give it a go and see how it works..

Looks like a good start! If I could find a 1/8" bit like that I'd be set at 6mm it wouldn't do things like battery slots or lightning slots but those can be finished by hand too. I also like the ability to pierce the material and make a cut without predrilling. You'll catch the bug and make improvements to your design as you go based on what your cutting

I'm not far off from the next version it's drawn up just waiting for money!

i figured that between my scroll saw and this table i should be able to do most things at this stage.. the one thing i will try is to see if a router bit will stand up to aluminium plate.. i figure if i make a arm then i might be able to copy it multiple times.. time will tell..

....and thus begins the next version, with a stiffer Bosch Colt clamp from a CNC mill. I'm getting really tired of using the stock base. It flexes a lot

drew up a cut sheet and decided to mock it up in Sketchup first- it fits!

my goal was to reinforce the router mount area and also allow a couple storage spots for G10. With this I can fit 24x12 sheets in each storage area. Thats a lot of G10! The router box area is more forward that the old router, and the arm will be longer too. The stand looks small but will fit both my shop vac and my water filter bucket, making this a self contained unit.

Mount arrived today, it's a work of art! They run $50 and ship fast! This should make for a very sturdy setup!

http://www.aquickcnc.com/

Btw, they have developed a interesting CNC setup, I have read up on it just a bit and it sounds very adaptable. I'll be looking at these guys when it's time to buy one!

That looks great & beefy for a mount.. Looking forward to the new one all done up..

Hey Jeff. When the new router is up and running, one piece that I thought would be neat is a rear shock tower for the rc10 Tekin conversion. Have you seen it? It's 4mm U-shaped piece of plastic. Maybe a good test piece?

I have a Tekin chassis, I'll have a look

Finally getting somewhere, got the base all screwed and glued, won't put the top on until I get the router mount finalized. I decided to get fancy and buy a dado set for the shelves

Hopefully I can get the router mounted tomorrow and get the top glued on. I would like to lay down a laminate over the top, to make the material glide more smoothly and also keep from gouging the MDF

I'm glad I went with the same styling as the benches. It looks overbuilt but it was a super simple construction!

Looks like a professional build! Nicely done...