I was cutting some aluminum to size lat night for my chip shield project, and was amazed at the surface finish I achieved.
The details:
- 7075-T6 1.5″ x 2.5″
- Jet 5×6 horizontal bandsaw
- 10-14 TPI variable pitch bi-metal blade
- 120 SFPM
- no cutting fluid
612×816 456kB
1224×1632 1217kB
I’ve decided it’s time to make some kind of chip shield, so I don’t get burned by flying chips anymore. My self imposed design requirements are as follows:
- cheap
- easy to install/remove
- simple to build
The following renderings show what I came up with.


Continue Reading…
I painfully learned the lesson(again) tonight that blue chips are hot! I was turning down some 8620 to make threaded inserts, and a 2″ long helix flew up over my head, and landed on the back of my neck. After a quick “hot hot” dance, and a bandage I was back to making chips. Five minutes later I took a 9 to the chin that left a nice little mark.
So remember everyone, if you’re making chips that look like this, don’t let them land on bare skin.

After a long Christmas & New Years, hiatus I started working on my shop benches again this week. On Sunday night everything was going well and I designed and built the alignment jig in about an hour. Monday night didn’t go as well. Part way through welding the first leg unit I ran out of wire. A quick look at the clock (11pm), and I knew I wasn’t getting any wire until the next day. Continue Reading…
For the final installment of wall charts, I have created this basic milling speeds chart.
Please note: I am not responsible for any personal injury to, or damages caused by an individual using the information listed on my website.
file: millingspeeds.pdf