Sander or router for smooth edge?

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Made a cover for my friends intake on this car. I think it was out of 22g, cut it out and I want to smooth out the edges. I tried to take it to the bench grinder but it's so thin it bent and threw the metal. Not literally threw it out of my hands but you know what i mean. This also happened to me using .063 aluminum.Which would be able to give me a really smooth edge and no sharp corners?Should I use a router with table and have interchangable bits or should I use a belt/disc sander. I don't have either so I'd have to invest in one or the other.These are the two I saw at the depot.Routerhttp://www.homedepot.com/h_d1/N-5yc1...&storeId=10051Sanderhttp://www.homedepot.com/h_d1/N-5yc1...&storeId=10051Torchmate 2x2 CNC with Flashcut CNC controlsHypertherm Powermax45 Esab ET220i Razorweld 195 MigRazorweld 200ac/dc TigTormach 770, Tormach xstechRazorweld, Vipercut/Vipermig, SSC Foot Pedal Dealer
Reply:I'd use some cloth backed sandpaper.
Reply:File, then emery paper on your finger, then scotch brite pad.I check everything for burrs with my leather glove.  I smooth things out a bit and then check with my bare hand.  That usually leaves things smooth enough to be safe.My name's not Jim....
Reply:Boostin called it for a zero dollar investment. On the other hand, if you are in production, a belt sander is pretty nice. However, that little delta unit is crap. Its fine for .063 aluminum, but is not very universal. Not enough power or surface area for general shop use. I suggest you get a 1 to 3 hp motor and build a 6" x 48" belt sander. You'll have a real tool then Of course use a finer grit for sheet material. 36 grit still leaves a sharp edge on 22 ga JasonXMT 350 MPA Dynasty 280DXSuitcase 8RC / OptimaSpoolmatic 30AThermco Ar / C02 mixerAssorted O/A gear
Reply:Originally Posted by BCRDOf course use a finer grit for sheet material. 36 grit still leaves a sharp edge on 22 ga Jason
Reply:I agree, a belt sander is going to leave a burr on the end of a sheet.  It's a handy tool to straighten up a ragged edge though.  On the last pass, I'll use the section of the belt that's not supported anywhere.  It curves a little more under pressure, and leaves a rounder edge.  You can also work on the roller, to get into a curved surfaceI also have several air belt files, and use them for shapes that the standing sander can't work in.  Also, the entire back of the belt is unsupported, so they're really good at rounding corners (same thing if you remove the back support on a 1" tabletop belt sander).A file can be used for all of this too, but files can chatter a lot on sheet metal.Still, in the end, for the smoothest edges, you're going to have to go over it by hand.  For this, I prefer cloth backed sandpaper over paper backed, because it's less likely to let you cut your fingers.
Reply:how about a rout-a-burr?  they are fairly cheap and very versatile.http://www.travers.com/product.asp?R...143-99-001-001http://www.penntoolco.com/catalog/pr...ategoryID=1710buy some extra blades and put in the handle.. Everyone that works with metal needs one of these..Last edited by brucer; 02-27-2012 at 05:03 PM.tackleexperts.comwww.necessityjigs.comhttps://www.facebook.com/groups/mach...dingequipment/
Reply:What the hell is a rout a burr? I've never heard or seen one. My friends had a block off plate for his car that was made off a CNC, these are the types of edges I want.Torchmate 2x2 CNC with Flashcut CNC controlsHypertherm Powermax45 Esab ET220i Razorweld 195 MigRazorweld 200ac/dc TigTormach 770, Tormach xstechRazorweld, Vipercut/Vipermig, SSC Foot Pedal Dealer
Reply:I think you need to re-state your question.  In your first post you mentioned 22ga and .063.  All of us are thinking thin sheet.  Now you're posting pics of what looks like 1/4" or better.  What exactly are you looking for?My name's not Jim....
Reply:Gamble first of all you shouldn't grind aluminum on a pedestal grinder of any shape or size.    that pic you posted  is of a milled part and looks to be at least 1/4 in thick  whole different story than what you are talking about . if you do much fabrication and welding at all  invest in a good 3/4 to 1hp upright belt/disk sander for metal  i have a 1hp Dayton  that i use the hell out of one of the most handiest tools i own . those tools you  have   links to from Home Depot are for small wood only projects" like building bird houses LOL " not for any type of metal work good luck .Chris
Reply:Originally Posted by GambleWhat the hell is a rout a burr? I've never heard or seen one. My friends had a block off plate for his car that was made off a CNC, these are the types of edges I want.
Reply:hi, if you decide on belt and disc i would go with 6"x 48" belt and 12" disc. If your location is chicago, check craigs list. heres a couple.http://chicago.craigslist.org/nwc/tls/2866564347.htmlhttp://chicago.craigslist.org/sox/tls/2862698573.html
Reply:Originally Posted by BoostinjdmI think you need to re-state your question.  In your first post you mentioned 22ga and .063.  All of us are thinking thin sheet.  Now you're posting pics of what looks like 1/4" or better.  What exactly are you looking for?
Reply:Originally Posted by brucerhow about a rout-a-burr?  they are fairly cheap and very versatile.http://www.travers.com/product.asp?R...143-99-001-001http://www.penntoolco.com/catalog/pr...ategoryID=1710buy some extra blades and put in the handle.. Everyone that works with metal needs one of these..
Reply:One we use from time to time is a Porter Cable random - orbital sander. Leaves a good finish , just depends on the grit of paper used.