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darsunt 05-16-2008 12:54 AM

Tool to remove metal?
I recently bought a cone shaped drill grindstone in the hope that it could remove metal fairly quickly from aluminum frames. But the metal removed stone faster than the stone removed metal.

Is there a grindstone or other drill accessory that can do this?

Maintenance 6 05-16-2008 06:31 AM

Use a carbide burr instead. Even a good quality stone will load up with aluminum and basically "clog" up. With the burr you'll want to find a speed that allows for removal of material without overheating it. Once overheated the aluminum will actually melt and stick and load up the flutes of the burr.

Brik 05-16-2008 08:35 AM

What are you trying to do? I'm thinking a grinder or a dremel depending on the scale.

darsunt 05-16-2008 12:45 PM

I want to modify existing aluminum window frames already installed. I want to do things like remove 1/4" of material from along one side.

Brik 05-16-2008 01:12 PM

Hmm - Thats going to be tough to do neatly. Those frames are narrow. I have heard of people using carbide woodworking tools to cut aluminum but I cant envision how to skinny up a frame safely.

When I was in highschool I worked in a hardware store and one of my jobs was to repair windows and screens. Often the frame was messed up too. If somone had a window in an alumium frame and wanted it 1/4" smaller I would take the following steps....
1) Remove the spline (the rubber that holds the glass)
2) Remove the glass (it will just lift out)
3) Disassemble the frame (Its held together in the corners with some type of corner piece either metal or plastic)
4) Cut the frame to the new size
5) Re-assemble the frame
6) cut the glass to fit the new size frame
7) install the glass and spline
8) charge the customer too much money

A similar process for screens.

Maintenance 6 05-16-2008 03:01 PM

I would try to think of a way to do it with a router. A carbide cutter does a good job of cutting aluminum. There are even specialty bits just for cutting aluminum. Store Front installers use them. You'd have to come up with a guide though.

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