Anyone have advice on milling the indents for the aluminum gear? I know about not generating too much heat.

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Comment by martin acton on February 21, 2012 at 12:55am

work carefully with a tungsten tipped wood router bit, it cuts the material just like a milling machine, and the heat generated is very little. The end result gave a very uniform fit around the bolting areas. Just don't try remove too much material too fast. Work slowly and hold the router very firmly to prevent from biting in and spoiling your job. I also used a radiused bit to shape the leading edges of the front gear.

Comment by Ralph Moran on February 6, 2012 at 10:40am

I am thinking about where the gear meets the fuselage. Thanks Chris, thats the sort of stuff I need to know.

Comment by Chris Aysen on February 6, 2012 at 6:55am

Always use some type of coolant when cutting aluminum. I would also use a 4 flute endmill just large enough to get the job done.

Comment by Ben Haas on February 6, 2012 at 3:34am

Are you talking about the indents where the gear mates with the cabin or down where the brake caliper needs to be relieved?

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