71 750-K Cafe Project

oldog said:
I did make the plates. I first made a mock up set out of 3/8 plywood to find the right spot for the pegs and controls. The aluminum plates were cut out and shaped with a drill press, jigsaw, belt sander and a router. Yep, pretty much all woodworking tools.
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You routed 3/8" AL plate to make those chamfered edges? What kind of bit did you use? Did you use a router table or a hand held router? How did you hold the piece in place while you did it? How hot did it get? Did you have a variable speed router? What speed did you run it at? I would have been terrified that the bit would shatter or did you use machine bits and not wood router bits. Can you tell that I want to do something similar?
 
Not to threadjack since it's technically part of it......

You can indeed use a router on 6061 t6 aluminum. 7xxx series will kick the living crap out of the bit and probably yank the router out of your hands. Don't. 2/3/4/5xxx series have their own issues so don't bother. However.....luckily 6xxx series aluminum alloy is the most common.

Bolt your plate down to something solid, hook a shopvac up to it and spray often with WD40.

fyi: I own a custom fabrication joint and even I've used this method. Expect to do some file/sandpaper cleanup and remember to use LOTS of WD40....
 
Thanks swagger. You know your stuff for sure. I wasn't even aware of the aluminum grade difference. I picked my aluminum from a scrap pile at a recycle yard.
 
For your rearset shifter rod you might look for a modern sportbike rod. Most are quite long then you wouldn't have to use the coupler. Machine work is pretty, a friend of mine calls that stuff "man jewelry" nice job.
Cheers, 50gary
 
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