[HELP] cutting/drilling

[marciklein1969]

I will be using 1.25 inch diameter square aluminum tubing for a consumer product and will need to cut to length, bore holes for a set screw, and debur for powder coating. I will receive the aluminum in 8-10 ft lengths and will cut them up to 6 ft. can anyone offer advice on machinery needed? i do need precision need a cost-effective solution. (image is conceptual only)oh, did I mention, i am not a machinist in any way..yet)

[ieezitin]

Cut your pieces on a regular 4" bandsaw $300. A small mill / drill can square the edges $1000. because your parts are made to tight tolerances you could make a drill guide jig and drill with a 18 volt drill $100.

A shop filled with the miscellaneous bits and pieces needed Priceless. its not hard.

Anthony.

PS welcome to the site.

[stevec]

1¼" Dia. brings "round" tubing to mind but I suppose you could mean 1¼`square tubing.
You mention "boring" holes for a setscrew, what is the wall thickness?
What is the "setscrew" size.
Need more info.
Edit, Disregard the above, I found the explanatory OTHER post! (still wondering about 1¼ Diameter)

[marciklein1969]

thanks for responding- the wall thickness will be 0.08 on one extrusion and at 0.12 in the other. set screw size tdb by engineer, the 1 1/4 is the width -sorry it is square not round.

[PixMan]

That wall thickness in aluminum is not going to be sufficient for a set screw of any significant size. You would be advised to TIG weld a boss in each location where you need a set screw and then tap it with an "STI" (screw thread insert) tap, then fit a Helicoil or Keen-sert steel thread insert.

[ScrapMetal]

Just a thought, is there any way you can get the stock delivered in lengths of either 6' + or 12' + ? It would really cut down on the amount of material waste and probably bring your costs down.

-Ron

[stevec]

(08-16-2014, 10:23 PM)PixMan Wrote: That wall thickness in aluminum is not going to be sufficient for a set screw of any significant size. You would be advised to TIG weld a boss in each location where you need a set screw and then tap it with an "STI" (screw thread insert) tap, then fit a Helicoil or Keen-sert steel thread insert.

Ken, I somehow doubt if the term "setscrew" is being used as we know it. Are you familiar with the type of extrusions she's talking about.

EdK , is there some way you can consolidate Marci's posts so there can be some continuity of reference?

[EdK]

(08-17-2014, 12:31 PM)stevec Wrote: ...

EdK , is there some way you can consolidate Marci's posts so there can be some continuity of reference?

Steve,

I deleted the duplicate post yesterday, if that's what you're talking about.

Ed

[stevec]

No Ed, all the different titled posts that are all about the same subject.
Actually, If she has an engineer to "spec things" why is she bothering us?