Tool Suggestions
 

So we're currently getting ready for the upcoming build season. What tools should we try to get with a budget of around $400.

Tools we have in our shop:
14" metal cutoff saw
Bench top drill press
Other basic hand tools

We have limited access to:
Mill
Lathe
Bandsaw

Does anyone know of a mini mill for aluminum that's in our price range? Or maybe a similar metal cutting tool that can handle side loads?

-Graham

Re: Tool Suggestions
 

A couple of hand power drills with bits, a dremel-type tool with bits, and a bench vise would be high on my list. With only $400 to spend Harbor Freight, garage sales, and Craig's List are you friends.

Re: Tool Suggestions
 

Well we already have those lol. We're looking for a good router or mini mill to cut aluminum.

Re: Tool Suggestions
 

I'm a fan of 1" wide belt sanders, very useful, we always bring one to competition with us.

Deburring tools, center punches, precision measuring tools, heat gun, etc are all useful.

Re: Tool Suggestions
 

A decent jigsaw with "medium" wood blades for cutting aluminum (the metal blades are great for steel, but gum up with aluminum).

And I second both the 1" belt sander and the Dremel. Our belt sander is probably the most used tool in the shop after the band saw and hand drills.

Re: Tool Suggestions
 

Thanks Allen

We'll definitely be picking up a center punch and caliper.

What exactly does a belt sander do??

Does the jigsaw work pretty well??

Re: Tool Suggestions
 

If you don't have a set of squares of various sizes, get one. Smaller ones with a 45-degree at the joint are particularly useful.

Seconding the belt-sander, we use that a lot. A bench-grinder and angle-grinder are nice, too.

More clamps are always a good thing, especially quick-grips.

One of these will make your drill press a lot nicer.

Re: Tool Suggestions
 

We use the belt sander to smooth every cut - remove sharp edges - even some rounding over, etc. If steel axles get burrs or marks they can be easily sanded away.

The jigsaw is great for rough cuts. We always take one with us to competition. We have a nice Bosch saw at our main build site - but I bought a cheap one at Harbor Freight that works great too.

Re: Tool Suggestions
 

Yes like Terry said the belt sander is used to smooth out pretty much every cut we make in the lab. We actually have 4 of them in our lab (purchased before I came to the team.) They also allow you to sand things to close to exact measurements. When you don't have a mill or a lathe, a caliper/ruler and sander can get you sort of close. It's much easier than hand filling everything. We used them make all of our spacers last year.

A few other tools I would recommend

• a pair of sheet metal snips for cutting thing aluminum and plastic. We use 09 Aluminum and 1/16" lexan and the shears cut through both very easily, often faster than taking something to a band saw.
• An arbor press, for inserting/extracting bearings, pinions, broaching keyways. If you have a broach, We just bought this set from Enco. It will let you put 1/8" keyways in different items.

Re: Tool Suggestions
 

You could find a mini-mill on craigslist in that vicinity, but it will need some elbow grease to get it running and you'll have to wait for the right one to show up because there are lot more garbage mill/drills than decent ones. If you have a drill press I think a tabletop lathe is more useful and you can definitely get a decent tabletop lathe for $400 on Craigslist. I would stay away from precision tools from HF -- when buying new you generally get what you pay for.

Re: Tool Suggestions
 

When you buy new power tools this late you should plan on the set up and training time. Our team has for years tried to have all new tools working by Dec 1.

Re: Tool Suggestions
 

How much raw materials does a frc team need during a regular build season? (For example, amount of money, which materials are needed, and how to get them?)

Re: Tool Suggestions
 

Well you are going to need a good amount of aluminum and maybe even some lexan.

I suggest contacting Johnson Controls and JemTech Machine shop in Middleton.

http://www.johnsoncontrols.com/
http://www.jemtechmachine.com/

They seem to have machining capabilities. These could be sources for materials and mentorship.

Re: Tool Suggestions
 

We're planning on doing something like this. Thanks for the advice

Re: Tool Suggestions
 

We spoke with a local metal salvage company who told us that they periodically are asked to "clean up" materials from bankrupt companies, and thus have brand new raw material (aluminum, steel, etc.) to dispose of. They offered to donate anything they have that we can use. Perhaps you can find a situation like that.

Re: Tool Suggestions
 

Thanks, how much aluminum is needed and what size should we get?

Re: Tool Suggestions
 

well it depends on what capabilities you have for cutting aluminum for the thickness. for are team we usually buy some 1*1 aluminum box along with some sheets of varying thicknesses of aluminum.

Re: Tool Suggestions
 

We have the capability to cut thick Al, but for the frame, is 2x1 better than 1x1 Al? And how thick of a Lexan do you think we need?

Re: Tool Suggestions
 

It's dependent on your construction methods for what type of box and for Lexan we usually keep some 1/16th and 1/8 on hand

Re: Tool Suggestions
 

I suggest you talk to a local company and see what they have. Our first two years we built with wood without even knowing that we had a local company that extruded aluminum for shipping across the world.

Re: Tool Suggestions
 

It is very dependent on your situation, but just as an example, we keep lots of .060 and .090 on hand. We also have some .125, and a bit of .25, and very little of anything thicker, save a few blocks. We've found that sheet metal is a more efficient and strong than lexan, and use it for most things on our robot.