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michair 12-04-2019 09:54 AM

Router table help
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Ok here is my issue we are a steam bending company and we currently draw our patterns on our die stock then cut out with a band saw. We have a router table that is 4ftx8ft and has a plunge of 24in. I would like to start using it to cut out our dies but they are 8 inches thick and very from 6in tall by 12in wide to 3ft tall by 6ft wide. We currently use the router to flatten the two sides of the diestock so its already laid down on the table so my thoughts are why not use the router to cut the die out making it more true and we will also have a digital copy if needed. so here is my issue the die stock is 8.5 thick we would need a 10 inch bit to be able to cut through it. I have looked for a half inch bit(for strength) 10inches long and not much luck. do they make such a beast? This would make my job so much more precise we already cut out our templates with it that we use to verify part after bent equal customers needs. Thanks for any and all input.

woodnthings 12-04-2019 10:03 AM

That's massive router table ....
That size is way beyond home shop and even the commercial tables I'm familiar with. To mill/rout an 8" section would require support a both ends of a bit OR a massive arbor 2" to 3" in diameter. A horiztonal milling machine came to mind immediately which is similar in principle:


I think you are talking about a machine that doesn't exist and you would need to design your own, but I could be wrong.

shoot summ 12-04-2019 10:45 AM

That is a seriously large item to route in one pass. Even with an initial cut, then a follow up with a guided bit that is way beyond normal router bits.

As woodnthings indicated you are likely moving towards some specialized machines that are much larger in scale.

One wild idea that might be worth considering is using a waterjet cutter for the forms.

TimPa 12-04-2019 12:59 PM

as mentioned from the woodworking world, and i can say from the cnc world, and 8" long x 1/2 bit will be a rare beast. but i think you will encounter huge bit flex and chatter from such a bit, typically as bits increase in ength, they also do in diameter. i would look in the 1" + diameter category. what is the collet capacity? is tghis a pin router?

_Ogre 12-04-2019 03:07 PM

change your thought patterns from bandsaw to cnc router :smile:
use 3/4 stock to make stack set of patterns and then your not limited to 8" either
cnc 2 alignment holes to pin or bolt the 3/4 stock into whatever width you need
glue, nail or bolt the segments together

easy peasy :wink:

michair 12-05-2019 10:16 AM

1 Attachment(s)
Our collet is up to 3/4 only. I agree on the bit flex that's why I came here to get opinions. I like the horizontal milling idea if I can find one fully automated. Not sure the boss will agree to spend that much but if you want a good job it costs real money. Out current router table is a shopbot with upgraded z access to 24 inch not the most expensive out there but does a great job flattening out dies and cutting patterns.

_Ogre 12-06-2019 03:17 PM

you really need to change your mindset from cutting 8 inch stock on that table
we have a cnc plasma cutter and do the multi layer dies all the time, different material same idea


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