How to cut a 2mm slot in this?

I have a cutter by CK Zenzes (? spelling) in among'st Dads wood working gear, it's like a little slitting saw welded on a 1/4" shank, I'v also made one similar by brazing a shank on the middle of the side of a bit of a broken industrial 12" hacksaw blade, and forming a tooth on opposite corners. Both these would work on aluminium.

Ian S C

I have an old used cutter for a key cutting machine, unfortunately its 32mm diameter and 1.3mm thick, any use? Photo of new one!

It looks as if you will have to make or customise a milling cutter but it may be less trouble to fabricate the tee slot and I think I would rivet it together with countersunk rivets.

Mike

I love asking questions on this forum. Experts sort out out my problem while I'm boozing at a family jolly.

Bit more background, Dick and Clive H identify the component, and with Gary are all thanked for focusing my attention on why it keeps failing!

The fridge/freezer belongs to my sister and is fitted in a cupboard. The fridge is on top and its door is joined top and bottom to the cupboard via slider rails. It is the lower component that breaks - they last about a year. The cupboard door has a hand grip running along the lower edge that people naturally use but it puts most of strain on one flimsy part, which eventually breaks. The close-up shows how thin the part is where it connects to the slider! (Bottle-top for scale)

Clive F's comments about 'barely enough material to do the job' and clearance are very relevant. It may be possible to beef the part up, though Clive H is right to worry about breaking the slide rail which is also flimsy, and he's likely right about the vacuum as well. More investigation needed.

For solutions, I'm spoilt for choice:

• Modify an existing tool like a woodruff cutter (Ed, Jason)
• Make a tool (Neil's Rufus Roughcut & Ian's butchered hacksaw blade)
• Misuse a tool ( Derek's router bit & Adam's key cutter.)
• Plane the slots (Jason & XD351)
• Hacksaw slots(Les & Mick)
• Make in layers & glue, screw, or solder ( Tim, Duncan & Clive F)
• Fold from metal (Blowlamp) - possibly how the part would have been made before plastics.

What happens next depends on what's in my junk box: a Rufus Roughcut or fly-cutter most likely.

Special Mention in Dispatches for Neil's 3D printer. I thought this was a good idea but it turns out my kids are unhappy about me blowing their inheritance on 'toys'. Put to me vigorously that a man with a garage full of tools should be able to fix a fridge door with what he already has...

Watch this space. Be a week or two but I will report again!

Dave

Taking account of your latest post the answer is blindingly obvious. Using jigsaw cut a 6mm slot about 60mm long across the cupboard door. Then use a 100mm long pan head screw through th door with penny washers each side and bolt through th fridge door, adjusting with nuts to each side of the fridge door. Cut off excess length of bolt with diamond blade in your Dremel or leave over length if you don't have one. The above in stainless steel but if you only have in ferrous paint liberally in whatever colour hammerite you have in an old tin.

This solution might not be as elegant as some suggested but it will help demonstrate to others the importance of a fully equipped and up to date workshop. Blacksmithing solutions are fine in rustic environments but the modern home demands more sophisticated tooling to provide the elegant solutions demanded!

As the components are available on Amazon I remeber seeing a long slider so perhaps fit two of these items to the slider? this would alve the strain on a single one and no machining.

Just had a look at our fridge freezer. These sliders appear to float on the rail, i.e. clearance top and bottom wrt the sides of the rail.. Before replacing the slider again, it might be a good idea to check if the rail is installed level and that the hinges that support the decorative outer door haven´t sagged. These kitchen hinges are a pet hate.

Thanks for the new ideas. Junk box failed me when I tried to make one of these earlier and I have to restock at my local metal emporium. Again. Meanwhile I'm visiting my sister on Saturday and will have a good look at the guilty fridge door and slider. It hadn't occurred to me that poor fitting might be a problem, but it's not unlikely.

If all else fails I'll take the cupboard door off and tell her distressed kitchens are fashionable again this year.

Cheers,

Dave

Totally agree . Rough up both surfaces and wedge a chunk of 2 part epoxy putty in there and explain that you had stuff in the workshop to do the job,...just not the way you'd have liked

pgk