Mini mill or handtools for this job (rectangle with slots)

Hello all

The aluminum pieces in the link below look reasonably straightforward to make. Question is, would a pair of these be a realistic diy weekend project and if so, would it be achievable with hand tools?

If a mini mill is called for, would a Sieg x1 or x2 be up to the job?

https://tsoproducts.com/accessories/tds-10-dog-stops-for-20mm-worktops/

Easily made with hand tools if a mill is not available. Any mill would do

Paul

Thanks Paul. How would I go about doing this? Sorry this may be a really basic question.

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... I've just looked at the photos: **LINK**

https://tsoproducts.com/accessories/tds-10-dog-stops-for-20mm-worktops/

MichaelG.

Jim if you have access to a Sieg mill then I would use it. It will give you a much better finish, repeated accuracy and in a fraction of the time you would take with hand tools. Although I have not made any of these I have recently made some aluminium adjustable brackets of similar proportions and with similar slots. They took minutes on my Sieg.

Jim,

A mill would be the quickest and easiest method but not too hard to do it with hand tools.. Drill a series of holes (smaller than the width of the slot) and use a round file to cut between them. Then use a flat file to finish the slot to width. Or just a hole at either end of the slot, use a round file to make it big enough to insert a hack saw blade and saw down each side of the slot. Finish with a flat file.

Paul.

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Did you look at the fourth picture in the sequence, Paul ?

MichaelG.

The slots are undercut so actually quite a challenge to make with hand tools. You would have make a lot to justify buying a mill.

Robert G8RPI.

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... You spoiled it, Robert

I was hoping that people might be encouraged to look for themselves.

MichaelG.

And with the larger slot being in the region of 25mm quite a large cutter for a small machine unless you opt for a smaller one and don't have rounded ends to the larger slot.

Just a thought as these in light alloy and are for woodworking use you could just about use a router on lowest speed. Make up a jig in MDF rough out blanks with a hacksaw, chain drill the through slot first.....

Robert G8RPI

Frankly ... Given the positive review of this product, and noting that these are really 'setting pieces' not 'clamps' ... I would say they are very good value at the price.

MichaelG.

I don't see why they couldn't be fabricated from two "L" shaped "sides" bridged with stepped ends to keep them rigid.

This would open up far more possibilities, as the steps could be cut with an end mill on any a small mill, or as Robert suggested, a router ( -table?), or you might even find that a suitable extrusion is already available..

It could be more easily fabricated in two parts with hand tools if only personal use is contemplated. Depends on why the poster might wish to make rather than buy.

They're fairly simple to make, but on such a small mill will take ages compared to the cost of buying them. Time better spent on actually using them.

If as you say they will be made from Aluminum and you have a woodworking router you can buy router bit for that purpose but it will take several passes as most of them are designed for thinner material

They are not precision machining jigs so why make them so complex ? They are used on a router/saw table and are located in drilled holes on a wooden top. The stepped slot is not necessary.

A simple slot in a piece of flat bar would be just as good and would not require the stepped location dowel/nut. It could be made from a piece of round bar with a tapped hole. The hand wheel could even be replaced with a standard bolt.

Paul.

In your position, I'd use hand tools.

But I would make the slot the right width to fit the studs and get rid of the awkward step and use washers under the clamp knobs instead.

Alternatively use a wider slot and make stepped washers, if you have a lathe.

<edit> it seems the studs are 'loose' in which case, Paul's alternative will work fine.

Neil

Edited By Neil Wyatt on 03/09/2019 10:41:16

If you already have their dogs( or just about any other make) then you need the recess particularly for thin work as the top of the dogs is larger than the spigot that fits in the euro standard 20mm hole of the MFT.

If I were making some I would consider a hard plastic as the bare aluminium will mark work without anodizing to stop it. Also kinder on cutting edges if you have a mishap. I'd also make the dogs with flats to fit into the wider groove so they don't rotate when the knob is tightened.

Edited By JasonB on 03/09/2019 10:52:35

Corian. Cut with router.