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Date: Thu, 03 Mar 2005 09:34:09 -0500
From: Ernest Christley <echristl@cisco.com>
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To: Rotary motors in aircraft <flyrotary@lancaironline.net>
Subject: Re: [FlyRotary] hand router milling
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kevin lane wrote:

> a regular carbide bit for wood cuts well.  the secret is to get the 
> larger diameter bit , otherwise they constantly clog up.


I found that rubbing the tool and work material with a candle really 
helped with the clogging and produced a smoother cut.  I've taken 5lbs 
of cast aluminum off my PSRU housing, starting on the drill press, then 
the table saw, then a 'drill saw', and finally a die grinder chucked in 
a hand drill.  I quickly learned to keep a candle very close. 

In fact, I could tell the table saw blade needed more candle by the way 
it would squeal loudly when it got dry.  After the cut, you could tell 
see where it got dry, because he aluminum sticks to the dry blade and 
gets dragged back through the kerf, then jammed back into material, 
producing a mottled, sickly looking surface.  On drill bits, the 
aluminum sticks to the side of the bit instead of being pulled out of 
the hole, and eventually bogs the bit down.   Sometimes it sticks to the 
tip, and the bit won't cut at all.  A little candle and the shaving flow 
out of the hole.