A table saw, belt sander, file, demmal, and a standard rail.

[hill160881]

A fellow AOer wanted to see how mutch i could take off the sides of a standard rail. Here were the results with the tools listed. Turns out aluminum is as soft as some hardwoods. Did not even dull the blade of the table saw.

[Tunaman]

Just be careful while running small parts like that through a table saw. It will grab the part and pull your hand right into the blade. Happens very fast, and usually the results are BAD!

[hill160881]

Thats why i screw it to a piece of ply wood at least 2 feet long so my hands never get close

Thanks though. Even after 12 years of carpentry work i am still afraid of that tool

[Smoothice]

Thats pretty sick!

I'd be more afraid of cutting my hand on the sides of that rail then the table saw

[maniacmechanic]

I'd be more afraid of cutting my hand on the sides of that rail then the table saw

Thats what I was thinkin !!
How much does it weigh now ???

[DevilMan]

Thats what I was thinkin !!
How much does it weigh now ???

Still too much... But there is a plan to get it ULE'd out of the inside as well as to chop off some of the back end to shorten/lighten it.

Not sure if he has a scale handy, but I'll weigh a stock one and this one when I get it back next week and let you know..... BTW, I gave you a call and left a message.

DM

[maniacmechanic]

Still too much... But there is a plan to get it ULE'd out of the inside as well as to chop off some of the back end to shorten/lighten it.

Not sure if he has a scale handy, but I'll weigh a stock one and this one when I get it back next week and let you know..... BTW, I gave you a call and left a message.

DM

Weight's ;
AGD slug rail 9.3 oz ( 263 gr. )
AGD E Mag rail 7.0 oz (196 gr. )
AGD ULED E Mag rail 3.8 0z ( 110 gr. )

I've got a R/T rail in the garage that weighs 2.3 oz ( 66 gr. ) and there a still a few grams to mill off of it

BTW, I gave you a call and left a message ,,,,,,,,,yeah I know , i'll get back at ya

[hill160881]

2.7oz and still needs ULed.

Shooting for 1.5oz

[kill-n-spree]

3 weeks ago, I was putting a new floor in my bathroom and was cutting some new subfloor underlayment out of 1/2 plywood. I was cutting the last piece and the blade binded up with the small piece I was cutting and it ripped it out of my hands so fast it pulled my thumbprints off. The wood flew off like a ninja star about 15 feet and smashed into my tiller. If I had not of been standing a little to the side, it would of easily chopped off my junk. My Dad was there and saw it and we just laughed because he said the look on my face was priceless. Table saws will **** you up in a blink of an eye.I had a good friend cut off all four fingers on a table saw.

[hill160881]

Yes very very dangerous tools. Its down to 2oz and still going. Lots to remove still.

[maniacmechanic]

be sure to leave a few crossbeams all the way up so it don't bow out in the middle , remember everything bolts to or through the rail

[hill160881]

ya i am not going any further on the through drilling and just going to hollow out the inside leaving just the important areas.

[hill160881]

done except for a bit of finishing.

So now it is 1.5 oz and needs only some finishing touches. There is not much left in on the inside of the rail. Still only using a dremmal, sand paper and a file.

[Magmerc]

Out of curiosity, which dremel tip did you use to do the milling on the inside of the rail?

[hill160881]

There were several size cylindrical burs 1/8", 1/4", and 3/8" But the 3/8 did the best work.

I used a router attachment with my dremmal to keep things strait.