Need tooling suggestion...

[harryball]

Before I go with a 1/4" straight cutter by default... I need to hog out a 1/2" deep pocket that's approx 5.5" x 5.5" in cedar and do it about 600 times.

Here's the catches...
Must be a 1/4" shank. I could work with a 3/8" cutting diameter though, just havn't found such a bit.

I need to keep power requirements low, the router is 1.1 HP and the machine is not high powered.

I need to work as fast as possible, would like to cut in a single pass.

Finish quality is not a big issue but I would like it clean enough to make a decent glue joint.

The cedar is mostly clear and I'll slow down for any knots found.

Any suggestions appreciated.

Thanks,
/RB

[myxpykalix]

I know to some i sound like a broken record recommending Centurion but the other day i bought a 1/4" straight cutter from them for my hollow spirals and i had to cut some nice aromatic cedar and grabbed the striaght flute bit and started cutting. I was afraid once i hit the knots they would pop out and go flying but the bit went right thru the knots without any problems and rather than catching it just sliced them like regular wood without any problems.
Now I generally go slow on all my cuts as i'm in no hurry so i can't recommend speeds or feeds.

[drodda]

Not sure any bit will get all 600 pockets clean without replacing every few hundred. I have found that you can go too slow with a bit and that sometimes the life of the bit will be doubled if you find the sweet spot in speed and feed in hardwoods. I have been really studying the chips coming off when cutting and adjusting till the chips look right for that cutter. 1/4" downspiral Whiteside is my goto bit for almost any cuts.

-D

[tmerrill]

Whiteside's #1021 bit is a 1/4" shank, 3/8" straight bit with 3/4" CL. Sells for under $13 online.

Any chance of have 2 routers available, one set to 1/4" depth, other to full depth? Two passes would go pretty quick.

Tim

[harryball]

Thanks Tim, I'll check that bit out, sounds exactly like what I'm looking for. The guy decided a 1/4" deep pocket would be fine so one pass will do it.

I'm helping him do this on his own benchtop CNC machine that arrived yesterday. I ran the project on my bot and made a sample thus verifying the design and files. The little CNC machine is cute but I had to make sure he understood it wasn't going to tear through the wood like my bot with a 3/8" rougher on a 4 HP spindle.

He plans on cutting 600 post caps over several months so this isn't a production rush either. He's a good friend... I just wish I could have talked him into a Buddy 32 but it was overkill for him, the little desktop should be fun though.

/RB

[tmerrill]

OK, I assumed a hand held router when I saw the 1.1 Hp which prompted my suggestion for a second router. That's why we don't assume!

These are quality bits, but will need some type of ramping entry stragegy - they don't plunge well.

No affiliation, but I get my Whiteside bits through www.woodworkersworld.net (http://www.woodworkersworld.net). Good prices and prompt service. The bit I referenced is $12.50 and their S&H is very reasonable.

Tim

[knight_toolworks]

if you go with 80% stepover this will help quite a bit with time. though you need to watch splinters they tend to jam up dc's when you have that much stepover.

[tmerrill]

If your dust collection system is overwhelmed by a 1.1 HP router turning a 3/8" bit cutting 1/4" deep, then you have bigger problems.

[drodda]

MY guess is that the dust collection is done by hand from the floor around the CNC. Shopvac style.

I also get my Whiteside from Alan at www.woodworkersworld.net (http://www.woodworkersworld.net) there is free shipping with a modest purchase and he ships the same day you order. He also offers volume discounts on 10 and 25 bit orders.

-D

[harryball]

His dust collection system is about 16 years old, it does a good job when you can get it started but it can make a lot of noise. He also uses it to cut grass, wash the cars etc... :-)

Once we get the last few kinks worked out of this thing we'll probably have it cutting some time next week. The machine came "fully assembled and tested"... 1 out of 4 axis is working. Waiting on parts now.

I think about 6 or so bits will do the job. I'll get an order together over the weekend and get the bits on the way.

/RB

[harryball]

I ordered qty 7 of the #1021 to get to free shipping.

I now need the 1/2" round over on a 1/4" shank. Does anyone know if the Onsrud 42-06 can run with the bearing removed? I don't need to plunge with it, we'll only be going around the edge.

/RB

[odulfst]

I highly recommend midwest cutting tools for any custom carbide application. They are almost unfair (for them) on pricing, and very quick on turnaround. They will work with you to make sure you get what you want.

http://www.midwestcuttingtools.com/

[odulfst]

I had a bit made with similar specs recently....we'll called it a "finishing rougher" or something. Basically a regular finisher with lots of reliefs. Also called a chipbreaker. I didn't do this, but see if they will cut the flutes deeper for you, that will help it be more free cutting in wood.

[odulfst]

2 flute by the way ;)