DIY home machining without the right kit?

[norty303]

Ok, so here's the conundrum...

I have 2 new projector cases where the top covers are very slightly too wide to allow the cover to be removed for adjustments, without also having to loosen the end plate screws.
The obvious solution is to take about 1mm off of the width of the lid, or to do the same on the mating face of the end plate.

However, I don't own a lathe or other machine tool.

I do have a router though, so I was thinking I might be able to upturn the router in something stable, and then using the edge guide bar and a straight cut bit, take a small slither off the edges of the cover (it's aluminium).
What do you more experienced folk think? Or should I just go and find my local machine shop and get them to do it for me?

Thanking you!

[Jem]

If it's only 1mm and you're dealing with aluminium I think i'd be inclined to scripe a line, clamp the plate between two pieces of sturdy wood and simply file it down using long strokes. In fact even though I probably have the necessary tools I still think i'd probably do it the way i've described ;-)

[Picasso]

table saw will do this job.

[kitatit]

If it's only 1mm and you're dealing with aluminium I think i'd be inclined to scripe a line, clamp the plate between two pieces of sturdy wood and simply file it down using long strokes. In fact even though I probably have the necessary tools I still think i'd probably do it the way i've described ;-)

Hi norty,

I think Jem is spot on here. I would do the same thing even with access to to other tools.

The router isn't a bad idea, I just think you will be able to fine tune the fit better using a file. If you decide to use the router, I'd go for something like these cutters.
http://www2.blackwoods.com.au/infoBA...4270&P=2026989

They shouldn't be too hard to find locally.

Good luck.
Kit

[badger1666]

i think i would go with a belt sander

[turbohead]

If the router is in a router table and you take very light climb cuts, milling aluminum in this manner is very feasible. The key is to having the router mounted in a table.

[norty303]

That might be just the ticket actually Badger. Wasn't sure if the metal would chew up the belt though.

[badger1666]

That might be just the ticket actually Badger. Wasn't sure if the metal would chew up the belt though.

do a youtube search belt sanding metal
cool tools like mini power files and stuff
no need worry about chewing up the belt , its all about putting the right pressure on it

[kitatit]

The belt will be fine but there is a good chance of rounding off the the corners.

[logsquared]

From all your speaker building you probably already have a bit like:

http://lh6.googleusercontent.com/pub...CPGHtAgeqDi9kT

You could clamp the aluminum on top of a good straight piece of birch ply or whatever you have and let her rip. Maybe spray a little WD40 on the cutter and work piece.