How do you cut Keyholes? Can I use drill press as mill?

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I'm trying to make keyholes in aluminum metal. I've tried Drilling a large hole around 1/2" in size , and then drilling a smaller hole about 1/4" in size. Then using a dremel cut off disk to cut a slot between the holes., Not only is that time consuming the result looks very amaterish.I think using some sort of mill is the answer, but they are expensive, so I thought about using my drill press. The metal is AL is it is pretty easy/soft to cut. What kind of bit exactly would I need for a set up like thisI typically buy my nuts and bolts from www.mcmastercarr.comthanks for any suggestions.
Reply:buy a mill and call it a day can be had for under 2k used a drill press is a drill press not a mill not designed for the side loads of the cutter might be a good idea to hire a machinist to run it too since the cost in broken tooling from you learning to use it is going to be more expensiveOr buy a punch press pretty much any monkey can run one so your employees will be able and cost will stay downMiller Xmt 350Lincoln Ln-25Ahp 200xSmith Gas Mixer AR/HTig is my Kung FuThrowing down dimes and weaving aboutInstagram http://instagram.com/[email protected]
Reply:Figure the tonnage you need to punch your material.  You can find mechanical punch at low tonnage for relatively cheap and fast.  You can purchase the keyholes dies.An H-frame press with die and holder would work.  Arbor press might work too.I wouldn't put a monkey on a mechanical press.Note he suggest only taking 10 thousandth of an inch per pass.  How many passes will it take for you to complete your cuts?Last edited by tapwelder; 01-05-2013 at 11:49 PM.
Reply:Originally Posted by tapwelderFigure the tonnage you need to punch your material.  You can find mechanical punch at low tonnage for relatively cheap and fast.  You can purchase the keyholes dies.An H-frame press with die and holder would work.  Arbor press might work too.
Reply:Drill press's are built to take the pressure up and down, not sideways....the bearings won't take the load and the overall frame is not built to have the rigidity needed.If you don't want to stand behind our Troops, feel free to stand in front of them.
Reply:Thanks for all the responsesMaterial is 1/16 inch thick 1x1 square tube ALI've never used a press so ill have to do some homeworkany recommendations?KeyholesWill be about 6" from the end of the tube so ill have to figure a way to insert die into the tube 6" and back it so the tube is not crushed in the pressThe other option I just thought of is to use my mini lathe from harbor freightStick a 1/4" milling bit in the chuck and put square tube in the tool holder assemblies that sound feasible or am I just gonna bust bits?Last edited by AluminumWelder; 01-06-2013 at 10:01 AM.
Reply:Can you use a nibbler to "connect" your 1/2" and 1/4" holes?XMT304 (school)SP125+ (home)HF 4x6 BandsawGood judgement comes from experience and much of that comes from bad judgement.
Reply:Originally Posted by wireheadCan you use a nibbler to "connect" your 1/2" and 1/4" holes?
Reply:If you are going to use your mini-lathe, and the material is thin soft aluminum, you might be able to use a keyhole router bit.  The bit will be made from the same high-speed steel as a milling cutter, has a broad starter head and a thinner slot-cutting shank.  Generally used on plunge routers in wood, the initial plunge makes the entry hole, then a small sideways motion cuts the slot.  Stop the machine at the end of the cut and withdraw.  Use two cross-slide stops to limit the travel at both ends of the cut.  If you don't have a cross-slide stop rig up some sort of mini-clamps to limit the cross slide travel.Call Woodcraft and see if they still have any of these in stock:http://www.woodcraft.com/PRODUCT/200...FQJx4AodsBcAbgIt cuts a 1/2" entry hole with a 3/16 slot.  Not quite the 1/4" slot you want but close enough that only a few strokes of a small file on each side of the slot will get it to 1/4" width.  - MondoMember, AWSLincoln ProMIG 140Lincoln AC TombstoneCraftsman Lathe 12 x 24 c1935Atlas MFC Horizontal MillCraftsman Commercial Lathe 12 x 36 c1970- - - I'll just keep on keepin' on.
Reply:Mondo thanks that looks almost perfectI've never used a nibbler but the few I've seen look like the jaws would not fit into such a tight keyhole, maybe there are micro nibblers?A jig saw would not work as the blade would reciprocated back and forth and hit the opposite side of the 1" tube.Last edited by AluminumWelder; 01-06-2013 at 12:15 PM.
Reply:With aluminum that thin, 1/16th, you could also use a  router with a keyhole bit. I've done it many times. The bit needs to be carbide. You'd need to make a jig to hold the tube still.
Reply:cool, good to know. I have a router as well. I think it would be easier to set up in the lathe because you can see the hole being cut.do you have any other recommendation on where to buy a keyhold carbide router bit? the woodriver one mentioned above looks like it is not carbide so it woudl dull quickly with aluminum or more likely just gall up as aluminum sticks to it.Last edited by AluminumWelder; 01-06-2013 at 02:02 PM.
Reply:Rockler will have them and so will Highland Hardware.Sears may also.  After reading one of the above post maybe the bit doesn't need to be carbide. You'd have more control on the lathe and it would be a lot more fun than a router spinning about 20,000 rpm's..
Reply:i'm going to get this one , it is perfecthttp://www.rockler.com/product.cfm?p...9&site=ROCKLERthanks for the suggestion.