Square Cuts On Aluminum Extrusion, No Mill Required

If you’re looking for the perfect excuse to buy that big, beautiful Bridgeport mill, we’ve got some bad news: it’s not going to be making perfectly square end cuts on aluminum extrusion. Sadly, it’s much more cost-effective to build this DIY squaring jig, and search for your tool justification elsewhere.

There’s no doubting the utility of aluminum extrusion in both prototyping and production builds, nor that the versatile structural members often add a bit of class to projects. But without square cuts, any frames built from them can be seriously out of whack, leading to misery and frustration down the road. [Midwest Cyberpunk]’s mill-less solution uses a cheap Harbor Freight router as a spindle for a carbide endmill, riding on a laser-cut acrylic baseplate fitted with wheels that ride in the V-groove of — you guessed it — aluminum extrusions. A fence and clamping system holds the extrusion firmly, and once trammed in, the jig quickly and easily squares extrusions that have been rough cut with a miter saw, angle grinder, or even a hacksaw. Check out the video below for a peek at the build details.

We love the simplicity and utility of this jig, but can see a couple of areas for improvement. Adding some quick-throw toggle clamps would be a nice touch, as would extending the MDF bed and fence a bit for longer cuts. But even as it is, this tool gets the job done, and doesn’t break the bank like a mill purchase might. Still, if your heart is set on a mill, who are we to stand in the way?

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Hackaday Links: October 25, 2020

Siglent has been making pretty big inroads into the mid-range test equipment market, with the manufacturers instruments popping up on benches all over the place. Saulius Lukse, of Kurokesu fame, found himself in possession of a Siglent SPD3303X programmable power supply, which looks like a really nice unit, at least from the hardware side. The software it came with didn’t exactly light his fire, though, so Saulius came up with a Python library to control the power supply. The library lets him control pretty much every aspect of the power supply over its Ethernet port. There are still a few functions that don’t quite work, and he’s only tested it with his specific power supply so far, but chances are pretty good that there’s at least some crossover in the command sets for other Siglent instruments. We’re keen to see others pick this up and run with it.

From the “everyone needs a hobby” department, we found this ultra-detailed miniature of an IBM 1401 mainframe system to be completely enthralling. We may have written this up at an earlier point in its development, but it now appears that the model maker, 6502b, is done with the whole set, so it bears another look. The level of detail is eye-popping — the smallest features of every piece of equipment, from the operator’s console to the line printer, is reproduced . Even the three-ring binders with system documentation are there. And don’t get us started about those tape drives, or the wee chair in period-correct Harvest Gold.

Speaking of diversions, have you ever wondered how many people are in space right now? Or how many humans have had the privilege to hitch a ride upstairs? There’s a database for that: the Astronauts Database over on Supercluster. It lists pretty much everything — human and non-human — that has been intentionally launched into space, starting with Yuri Gagarin in 1961 and up to the newest member of the club, Sergey Kud-Sverchkov, who took off got the ISS just last week from his hometown of Baikonur. Everyone and everything is there, including “some tardigrades” that crashed into the Moon. They even included this guy, which makes us wonder why they didn’t include the infamous manhole cover.

And finally, for the machinists out there, if you’ve ever wondered what chatter looks like, wonder no more. Breaking Taps has done an interesting slow-motion analysis of endmill chatter, and the results are a bit unexpected. The footage is really cool — watching the four-flute endmill peel mild steel off and fling the tiny curlicues aside is very satisfying. The value of the high-speed shots is evident when he induces chatter; the spindle, workpiece, vise, and just about everything starts oscillating, resulting in a poor-quality cut and eventually, when pushed beyond its limits, the dramatic end of the endmill’s life. Interesting stuff — reminds us a bit of Ben Krasnow’s up close and personal look at chip formation in his electron microscope.