When manufacturing aluminum doors, the task that requires the highest level of skill and precision is fitting the handle and lock. If the slot or cutout made inside the aluminum profile to fix the lock becomes crooked or its size goes out of alignment, the lock will never seat perfectly inside the frame. In aluminum fabrication work, a router machine is used to extract this lock slot completely perfect and straight.
Many new craftsmen make mistakes while operating a router machine, which causes the aluminum material to get damaged during cutting or results in the machine's drill bit breaking. In today's detailed post, we will learn how to use a router machine professionally and what the correct technical method is to extract a lock slot in a door.
1. Preparation of Router Machine and Essential Tools
Before starting the work, it is mandatory for you to have these things:
- Copy Router Machine: A high-speed router specified for aluminum cutting.
- Correct Size Drill Bit (Router Bit): Generally, a 5mm or 6mm drill bit is used for aluminum lock slots.
- Measuring Tape and Marker: For marking the position of the lock.
- Cutting Oil or Spray: To keep the drill bit cool and ensure smooth cutting.
2. Step-by-Step Method to Extract a Lock Slot Using a Router Machine
To extract the lock cavity or slot in an aluminum profile, mandatorily follow these stages:
1: Measuring and Marking with a Measuring Tape
First of all, on the handle-side aluminum profile of the door, mark the handle position from the floor level upward at 36 inches to 42 inches, according to the customer's preference. Now, place the lock body over the profile and mark its exact length and width perfectly with the help of a marker.
2: Fixing the Material onto the Machine
Place the aluminum profile on the base (bed) of the router machine and tightly secure its pneumatic or manual clamps. Remember, if the material moves even slightly during cutting, the slot will become crooked, and the risk of the drill bit breaking will also increase.
3: Setting the Guide and Size of the Router Machine
A guide plate is installed at the back of modern copy router machines, on which lock sizes are predefined. If you are using a manual machine, set the machine's stoppers to the left, right, upper, and lower limits according to the lock marks so that the drill bit does not go beyond the specified size.
4: The Process of Cutting and Extracting the Slot
Turn on the machine and let it reach full speed. Now, holding the handle of the router, slowly lower the drill bit into the aluminum.
- During cutting, mandatorily spray a little cutting oil or kerosene onto the drill bit so that the aluminum does not melt and stick to it.
- Instead of jerking the machine, operate it slowly, first in a straight line, and then clear out its width. Always move the router in a uniform sequence so that the inner edges are cut completely clean.
5: Lock Fitting and Checking
After completing the slot, turn off the machine and clean away the aluminum shavings. Now, insert the lock body inside the slot to check whether it sits smoothly or not. If a corner is binding anywhere, clean it lightly with the help of a file and tighten the screws.
Important Technical Precautions While Operating a Router Machine
- Safety Glasses: Fine particles of aluminum fly off during cutting, so mandatorily wear safety glasses on your eyes.
- Fitting of the Drill Bit: Before starting work, check that the drill bit is completely tight and straight inside the router's collet chuck. A loose drill bit can damage both the material and the machine.
By using the router machine according to these technical principles, the fitting of the locks in the doors made by you will turn out completely perfect and beautiful, just like a company finish.
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