Alupanel Bit Selection

[jim_rutske]

Botters, would it be possible to cut Alupanel with a regular two flute upcut? Has anyone tried this with success? One Pass or two?

Here is the background. I have a quick turnaround job of cutting Alupanel into 14"x14" signs with cut-out text in the center. Last week I did my homework and read through the forums on other botters experience with alupanel & dibond. I ran a few tests to see if the bits I currently own would get the desired cut quality on a scrap piece.

I ran 1/8 Single O Flute straight bit with ok but chattered results. I ran a 3/16 O flute spiral upcut with much better results but the bit will not fit into the required text sizes on the sign. This stuff is miserable to hold down on the vacuum table so I ordered Russ's WidgetWorks PRT pressure foot. It will be here tomorrow. Russ was very helpful and extremely friendly. Excited to use it!

I also ordered 1/8 O Flute single spiral upcut from Ballew Saw and Tool. Ballew's checkout cart is miserable at best and it messed up my order. We called to get it straightened out and they were about as rude and unhelpful as I have experienced in years. Needless to say our rush order was promptly cancelled. Which leaves me in a bind for "the perfect bit" and raises the question of using a regular two flute upcut and not a single O Flute upcut.

Using a regular two flute upcut could it be possible to succesfully cut the alupanel in two passes, using the second pass to come in on a .02 or so offset to give a better edge finish? I'm holding on to my last spare piece of alupanel to test with the pressure foot and my final bit choice. I appreciate your time, any insight, and guidance you all can offer. -Jim

[jerry_stanek]

I use a 2 flute up cut 9/32 bit to cut dibond.

[brian]

I've cut quite a bit of it with a straight 2 flute.125 bit from Centurian.
I've had good results at 10500rpm at 1.5IPS
I also have the pressure foot and found it really helps with any intricate work.
You can tell when your bit is getting dull as it will leave a burr on the finished product.

Brian

[jim_rutske]

Thanks Brian and Jerry. I have a two flute 1/8th spiral upcut, I will give it a go when I get the pressure foot tomorrow. I have read nothing but great things about the pressure foot. Brian, I'm going to try your settings and see what I get from it. Thanks guys

[knight_toolworks]

I have cut it with up and down and straight. I would think a 1/8" upcut on 14x14 would hold down ok. but if you are desperate use a straight bit. it cuts ok with one. I have used down to a 1/16" straight bits and hte parts stay in place. but I have the pressure foot so I use an upcut now jsut a 2f endmill 2ips 8k single pass.

[jim_rutske]

THanks Steve. I'm going to run the test this evening. I will report back how the different bits and settings work out. -Jim

[ssflyer]

Jim,

I'm surprised about your experience with Ballew saw & Tool. I agree with you about their online cart, so I always just call. I've ordered several Onsrud bits from them, and usually when I call, I got Jack Ballew. Even though the website has what I consider ridiculous shipping prices, when I order, I simply ask him to drop the bits in the mail - cheap and fast.

I hope your experience isn't normal for them, these days!

[hh_woodworking]

I have always had great experience with Ballew and they are very helpful to me

[knight_toolworks]

a strait bit makes a little work removing the scrap off the edge but not as bad as a downcut. but it does not reweld really. Buti ti s nice using the pressure foot and a upcut bit then you can just brush or blow off the dust.

[jim_rutske]

I was really surprised at my experience with Ballew as well. I had heard such great things from the forum. I put in my order late at night after store hours, so I just used their cart. I probably should have waited to talk to a person the next morning. It was nearly a $300 order too, with the other bits I needed for replacements/upcoming foam jobs. I normally order from Fred at Centurion but he doesn't carry the 1/8th O up-cut. No worries I have a bit solution and I will place my order back with Fred for the remaining bits.

[jim_rutske]

The pressure footworks great! I had to do some modification to my dust foot to get it all to marry up, but she is working as well as expected. I used a single straight 1/8 bit 1.5ips at 13k RPM.

Now that the job is successfully done, I'm going to go back and figure out a way to get better dust collection. As you know Alupanel/Dibond does not vacuum up easily at all. I need to somehow get a better dust skirt to material seal.

I appreaciate this awesome forum and all who provided guidance. I did the job without a single mis-cut or wasted material. :)

[knight_toolworks]

if you used a straight bit why did you use the pressure foot? no need for both.

[jim_rutske]

My first batch of three signs I used an upcut/pressure foot. I wanted to see how a straight would compare and swapped out bits, but left the pressure foot on. I liked the results of the straight bit as it cut all the way through and gave a great bottom finish. I just left the pressure foot on assuming it couldn't hurt and might save a piece. I didn't loose a single sign. Much better than my test runs before the foot.

[fozzyber]

I bought somn bits from these guys http://www.rlschmitt.com/
I really like their single flute up cut 1/8" , cheaper than onsrud' cuts just as good or a bit better....
Also never had a problem with ballew' was really nice when I called.

[jim_rutske]

Thanks Jerry I will give them a call this week.

[fozzyber]

Also I like to cut sign a bond lite, dibond ''face down'' with a up cut bit in reverse