how to clean up aluminum letters.

[Steve knight]

I have a sign job that requires 1/4" thick aluminum letters.I needed a test sample to show the customer so I bought a bar of 6061 and cut it on my cnc router. the edge is a bit rough to leave as is. how to sand them to get the edges to look even? or use a file? use a spindle sander?
not sure if I need to do the face I guess it depends on if it is scratched. that I can hit on a belt sander so the faces are easier.

[Paul Atkins]

Different cutter? Take a micro amount off in a second pass? Seems like the fastest would be to let the machine do it while it's set up. Bead blast?

[Steve knight]

I used a onsrud o flute and I tried a cleanup pass and that did not make a difference.

[Keith Outten]

Depending on the size of the letters and the extent of the burr you might be able to clean the letters up using a vibratory tumbler and get a great finish to boot. HF sells them in two sizes, I recently bought the small one to expriment with various materials. You can polish brass and aluminum real quick and painlessly.

[Steve knight]

I used a onsrud o flute and I tried a cleanup pass and that did not make a difference.
well today I found if the finish pass was a climb cut it is much better.

[Steve knight]

Depending on the size of the letters and the extent of the burr you might be able to clean the letters up using a vibratory tumbler and get a great finish to boot. HF sells them in two sizes, I recently bought the small one to expriment with various materials. You can polish brass and aluminum real quick and painlessly.

I have been wanting one I thought it would flatten the backs of plane irons years ago. but it would not do anything to the edges would it? they are 6" tall letters.

[Keith Outten]

It depends on what media and grit you use. Ground walnut shells will only polish, you might have to do a little experimenting with different types of sand.

[Robert Alexander]

I have a sign job that requires 1/4" thick aluminum letters.I needed a test sample to show the customer so I bought a bar of 6061 and cut it on my cnc router. the edge is a bit rough to leave as is. how to sand them to get the edges to look even? or use a file? use a spindle sander?
not sure if I need to do the face I guess it depends on if it is scratched. that I can hit on a belt sander so the faces are easier.

How about a small angle grinder or die grinder, with a Scotch Brite fine or meduim hook and loop pad or SocAtt pad.
Where I use to work we used them all the time to polish and sand aluminum. They come in sizes as small as 3/4", up to 4 1/2". They can get into tight corners, and take out marks without digging into the material.

[Bryan Cowan]

Depending on the size of the letters and the extent of the burr you might be able to clean the letters up using a vibratory tumbler and get a great finish to boot. HF sells them in two sizes, I recently bought the small one to expriment with various materials. You can polish brass and aluminum real quick and painlessly.

Which one Keith? http://search.harborfreight.com/cpis...bler&Submit=Go

[Bryan Cowan]

I used a onsrud o flute and I tried a cleanup pass and that did not make a difference.
well today I found if the finish pass was a climb cut it is much better.

Steve,

What speed and feeds were you using? I plan on cutting our 1/8" aluminum sheets on Friday with a Onsrud SE Solid Carbide Upcut Spiral O Flute, 63-622 bit.

[Tony Dietz]

Have you thought about having them waterjet cut?

[Steve knight]

I found how to cut them better. though waterjet would be good I may not make as much money off of it. but if I have a large job I may sub it out.