Cutting metal with a router

[nobody]

Im thinking of making a control panel out of lexan and then placing a metal sheet over it with a  pattern cut out of it so i can make it glow. Im just wondering wheather you can get router bits that will cut metal (i want to make stright cuts). I suppose i could use a hacksaw but im pretty sure that wouldn't give me the crisp edge i want

[NinjaEpisode]

You'd probably be better off with a JigSaw using a metal blade.  Use a straight edge to line the JigSaw up and run along that line.  You'll still probably have a few metal shavings and burrs that need to be gotten rid of, but nothing a file shouldn't be able to take care of.

[chasmosis]

While I am not an expert on using routers, my thoughts are that it's an extremely bad idea to try to cut any kind of metal using a router.  There are so many other tools much better suited to the job.

Try dremel tools or a 4 inch grinder with cut-off wheels.  Jigsaw's or a Sawz-all (reciprocating saw) would work well also. 

You'd probably be better off searching out a metal shop which could cut and bend the metal to your specifications for probably not that much money (when compared to the amount of time that you may invest in failed attempts).  If you go this route make sure you have a picture/diagram of what you want and be very clear with them about what you want.

[rdagger]

If you decided to use aluminum than a router would work well.  A high speed steel bit would probably work better than a carbide bit.

[nobody]

If you decided to use aluminum than a router would work well.  A high speed steel bit would probably work better than a carbide bit.

really? as that is what i was thinking of using. A bit more expensive but better looking then steel

[PoDunkMoFo]

What kind of pattern are you cutting in the metal.

You might consider making a template out of wood.  Clamp the wood over the metal and let it guide you.  Tried to find an example of this on-line but don't have the time right now.  Others here may chime in.  I'm sure there are competent woodworkers who could give a better explanation than mine.

FWIW

[Crazy Cooter]

There are some metallic laminates that you could use.  It might be exactly what you're looking for.  They should be available anywhere "regular" laminate is.

[nobody]

There are some metallic laminates that you could use.  It might be exactly what you're looking for.  They should be available anywhere "regular" laminate is.

i shall go forth and look, hopsefully this will eventually turn out great (not sure when i can start building it

[rdagger]

There are some metallic laminates that you could use.

[DrewKaree]

DO NOT use a router to cut metal.  The metal coming off of it will be hot as all get out, and at the RPM's of a router, you have absolutely no idea where they'll be spitting 'em out and in what direction. 

Use a punch, a dremel with the proper bit, a jigsaw, a drill, ANYTHING other than a router.

[Gamecab]

Router+Cutting Metal = Pain

Trust me

[Veinman]

As painful as routing lexan was, there is NO way I would attempt to route metal. And if you were so inclined (and wearing a kevlar body suit), make sure there is no one around.

[Xiaou2]

 To cut metal decently -  get a tablesaw, then attach a metal cutting wheel to it.  They are fairly cheap, and work very well.

 

[nobody]

 To cut metal decently -  get a tablesaw, then attach a metal cutting wheel to it.  They are fairly cheap, and work very well.

 

yeah but a table saw != small pattern

i think im going to go with a jigsaw, i have plenty lying about and the blades are pretty easy to replace. Should aslo allow me to get the pattern i want and once ive filed it should have a nice edge

[elvis]

I'm currently doing some work on my next cab with stainless steel.  I'll tell you now, it looks fantastic, but working with it is a royal pain.  Stainless is harder than normal steel mind you, which is proving to be quite nasty on my drill bits (which are admittedly not the best quality to start with, but still not "cheap" by any means).

If you can get away with metallic laminates, use them.  There's stuff out these days that you would be hard pressed telling the visual difference between them and the real thing.  Plus it means being able to use your tools for multiple jobs!

[Avery]

If you are making big, low detail cutouts (say a couple big ovals) then I'd go with the jig saw.  This is very much one of those let the tool do the work kind of jobs.  Forcing it will just make your life harder.  Cover the top with contact paper or something to keep the saw base from scratching it up so much.

If you are making small or highly detailed cutsouts (a bunch of little stars and on big one in the shape of a guy in a space suit) rough out your shape with a drill and jigsaw and then use a jewler's saw to cut it to the shape you ultimatly want.  They're about $10-15 plus another buck or three for a pack of blades.  Needle files make cleaning this sort of thing up a lot easier.

If you are doing something thin enough you can use a shear of some sort or even a razor knife.

There's also the cold chisel, which is remarkably efficient for some purposes, though 1/8th aluminum, which someone mentioned, would tend to bog it down.