What is the most effective way to slot an uncut aluminum spinner? I'm talking about cutting out two or three slots for the propeller blades. I don't think my trusty Dremel tool can do the job.

I used my Deremel tool but what a pain that was. Here is what I am going to do next time, after I draw the outline of what need to be cut I am going to drill a bunch of holes to remove as much material as possible before reaching for the trusty dremel tool. or making Friend with somebody who has a milling machine.

This may sound crude, but I use my bench grinder. I mark the slots and then stay inside the lines. When its fitted, I file off the edges.

Tom what size is bench Grinder. I bought a disk grinder from Harborfrieght for $19.99 ,probably it was the best $20 I have ever spent. Thanks for the idea Tom the bench grinder might do the job.

FOXX My bench grinder is a Sears 5 inch. It has a wll worn disk that is perfectly rounded on the edges so that I can get the shape I need at the end of the prop slot. Your grinder should be fine.

I came up with a more effecient way to use my dremel. I use a 1/4" router bit. If you're CAREFUL, it works excellently. A profile gage (from the hardware store) is a great way to transfer the profile from the prop to the spinner.

-Aaron

This is basic Metal Shop 101 stuff guys. NEVER, NEVER, NEVER grind aluminum on a bench style grinder with a stone type abrasive wheel. The wheel can and will load up with aluminum, go out of balance and explode. I've seen it happen with frightening results.

Steve, Thanx, Didn't know that. Never took shop. I didn't realize it could be dangerous. Time to try a different method.

If you use Elmers poly and some foam to fill the spinner let it cure
of course then you have some backing it makes it easyer to then
melt arwy the foam with acetone or anything to give support to
the material being cut. CU

Hello,
I have a bunch of metal working tools in my garage so I'm pretty fortunate. I have a floor standing drill press that I have an "x-y" vise mounted to the table. This vise (available at Sears- through the catalog- for about $100.00) allows me to move my work both for and aft and side to side. It turns your drill press into a poor mans mill. I have some round carbide type cutters (I call 'em Burrs but I don't think that's correct) and I move the table up until the cutter and the spinner are at the same height. Then I move the spinner INTO the cutter and quide the spinner using the 2 handles on the vise.
Here's a photo of a typical spinner mocked up in the vise. I would have raised the table up a few more inches but the basic idea is conveyed here. They make smaller vises for smaller drill presses so one wouldn't have to spend a ton of many to get a similar setup.
I second the comment on aluminum and grinding stones--don't do it!!!!!!

Alu grind isn't easy I use a lot of cheap
dimond the don't load up like some say.
CU

I use my dremmel with a cut off wheel to cut the main large chunk out getting as close to the lines as possible. Then I finish with a carbide burr. I have found that frequent dripping of Tap Magic while using the burr speeds up cutting, keeps the burr from loading up and yields a nicer finish. I can usually cut a 2 blade aluminum spinner and balance it in about a half hour.