1/8" Aluminum for top plate?

[Sherman]

Wear ear protectors !

I am in the process of building a modular chasis -- the idea comes from taking apart various HP and Krohn-Hite equipment -- as I have a little milling machine it should be very easy to use 0.093 aluminum sheet for the sides, top and bottom...

I would love to have a milling machine! Of course then I'd have to take the time to learn how to use it. A friend of mine has one and the parts he is able to turn out are beautiful. He has made knobs from aluminum and brass that are stunning.

I think though that I'll start with my table saw and drill press for this project. I only have so much cash available so if I got a milling machine I wouldn't be able to actually build my amp!

I'm hoping to make the base from some Corian material I have (a large sink cutout). With a polished aluminum top it should look pretty good. I think I should be able to cut the Corian with my router.

 

[pinkmouse]

I think I should be able to cut the Corian with my router.

Routers work fine on Corian, just cut slowly and use sharp, good quality bits, though for worktop thickness you really need a powerful 1/2" unit. Oh and wear a mask, the dust is very nasty.

 

[rcavictim]

Just before Christmas I bit the bullet and decided to build a plunge router table with a foot bar pedal that would make full use of the router's plunge capability. I have a project that requires milling a precision slot into 1-1/4" thick lexan. The table works really well. I still need to finish the fence and add a power switch and dust collection port.

I've observed that most tools store router tables are way overpriced junk and I've never seen one offering the plunge capability feature.

 

[jackinnj]

So for cutting the slot: I could use a 3/32nd end mill, or would a woodruff keyseat cutter be better?