Filing out aluminium box section.

Scougar

Scougar

Scougar

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Hi chaps,

I've been working on a small project for a while now that is basically taking a paintball gun and making it magazine fed rather than via a hopper/loader.

http://www.ukscenario.com/forum/viewtopic.php?f=184&t=37110

The other project is my prototype box magazine for the paintball gun above:

http://www.ukscenario.com/forum/viewtopic.php?f=184&t=37001


The question: In the first link, you will see I have used some aluminium box section and I need that to be filed out by a couple of millimeters on the inner edges (the narrower sections). So far I have been using a diamond file and making exceptionally slow progress in removing material; I have also used a rotary tool but that was really not any quicker. Anyone got a bright (and cheap) idea to get that material removed quicker so the magazine can fit?
 
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As said if you know a friend with a mill (doesn't have to be a CNC) that would be easiest.

No need to use a diamond file they are for hardened materials really. One of your files looks more like a rasp, so thats not ideal.

Vallorbe make very good files, not cheap but worth it imo. Also, keep the file clean, ali clogs up a lot, clean it by filing some brass occasionally.
 
Tubes said:
As said if you know a friend with a mill (doesn't have to be a CNC) that would be easiest.

No need to use a diamond file they are for hardened materials really. One of your files looks more like a rasp, so thats not ideal.

Vallorbe make very good files, not cheap but worth it imo. Also, keep the file clean, ali clogs up a lot, clean it by filing some brass occasionally.
Click to expand...

I wasn't using the rasp; Wooden cabinets for storing wood over winter were also being built. I will go and see if I can get a better file, more suited for aluminium. I was using what was to hand, and unfortunately so far it's taken me about 4 hours of filing, maybe more without getting that far.

Cosimo said:
Maybe a Dremel will help....
Click to expand...

I have already used a rotary tool (See original post), and didn't get very far with it, I did however use up all my rotary sanding tips lol (and too be honest the bar's were not really long enough, and I also worry about causing ridges in the material that would make the magazine harder to slot in.

dirtychinchilla said:
Angle grinder
Click to expand...

On the inside? It's totally unsuited, but thanks. (and yes, I have one).
 
Why use a diamond file on aluminum?

Usually use them for tungsten carbide and hardened steel.

Trouble with aluminum is it clogs the teeth on the file, chalk helps to stop this, but you need a file with coarser teeth, a Type A flat file, or a proper file for aluminum, basically 'B astard Cut.

I have a coupe of NICHOLSON type A files, got them years ago.

http://www.ebay.com/itm/NICHOLSON-00047N-Flat-File-10-In-Double-Type-A-Aluminum-/221230041661

and with rotorary burrs, there are special ones available for aluminum, they have a different cutting profile to stop clogging.
 
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Nightglow> I used the diamond file because it's what I had to hand. Thanks for the tips, I'll see what I can pick up in that cut :)
 
dirtychinchilla said:
Sorry, I forgot about the inside element of it!
Click to expand...

I don't think I'd trust myself to use one on the outside either, they can be pretty viscous, and not very uniform. Maybe a grinding disc would have worked but I would still have need a a wide grinding surface which isn't typical for an angle grinder (that I've seen).

I will most likely look at another file as suggested by the other chaps :-)

Thanks for all the input guys :-)
 
If you have access to a pillar drill and a vice I'd just use the side of a HSS drill to 'mill' the soft aluminium away.
 
I do have a pillar drill and a vice in the back of the garage. HSS Drill? I'd have to look that up.

HSS: Hardened Stainless Steel?
 
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