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  1. #1
    Join Date
    Jun 2021
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    Missouri
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    Default Need advice on cutting grooves in aluminum rod

    Hey, guys. I was wondering if it is possible to effectively and inexpensively cut grooves for O-Rings in aluminum rod without a lathe? I have a small project where I want to make a custom hydraulic piston, but can't justify the expense of a lathe. It seems to me that aluminum is soft enough that there should me some kind of tool similar to a pipe cutting tool that could cut grooves, but googling around has gotten me nowhere. Any ideas would be appreciated.

  2. #2
    Join Date
    Sep 2019
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    Nagambie vic
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    22

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    Depending on the size of your work piece but could you hold it in a pedestal drill to turn it and use a cutting edge to cut the groove? I’m just trying to think outside of the box Need advice on cutting grooves in aluminum rod I’m obviously not trained in engineering or machining but have seen lots of improvisation after working in agriculture for the last 15 years Need advice on cutting grooves in aluminum rod

  3. #3
    Join Date
    Dec 2005
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    South Australia
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    Default

    A appropriately size round file and a vice would do it with some judicious care.

  4. #4
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    Jun 2021
    Location
    Missouri
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    Default

    Quote Originally Posted by Ando81 View Post
    Depending on the size of your work piece but could you hold it in a pedestal drill to turn it and use a cutting edge to cut the groove? I’m just trying to think outside of the box Need advice on cutting grooves in aluminum rod I’m obviously not trained in engineering or machining but have seen lots of improvisation after working in agriculture for the last 15 years Need advice on cutting grooves in aluminum rod
    I've actually seen a couple of youtube vids doing this, but I also don't have a drill press unfortunately. If it comes down to making a hardware purchase though, I'd much rather buy a drill press than a lathe. Thanks for the input.

  5. #5
    Join Date
    Jun 2021
    Location
    Missouri
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    Quote Originally Posted by China View Post
    A appropriately size round file and a vice would do it with some judicious care.
    I'm not 100% sure my hands are that steady, haha. I suppose a jig might help with precision. Thanks for the idea!

  6. #6
    Join Date
    Apr 2012
    Location
    Healesville
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    2,129

    Default

    If you dont have the skills or the machinery to do this then you need to find a machinist local to you, at least get a quote.....

  7. #7
    Join Date
    Nov 2007
    Location
    melbourne australia
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    3,228

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    Could you improvise something with a Dremel? Like in the picture, only with a hole for the aluminium rod to pass through at 90 degrees to the Dremel bit.
    Attached Images Attached Images
    Chris

  8. #8
    Join Date
    Oct 2004
    Location
    Southern Highlands NSW
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    Default

    Would it suit you to buy a used lathe, do your job and resell it?

  9. #9
    Join Date
    Sep 2009
    Location
    Newcastle
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    341

    Default

    O rings require a properly sized groove with an appropriate finish. If you are doing this for a hydraulic piston then I don't think you can do it without a lathe (or using a mill as a lathe)

    If it was purely decorative, then sure whatever.

  10. #10
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    Jun 2021
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    Missouri
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    Quote Originally Posted by shedhappens View Post
    If you dont have the skills or the machinery to do this then you need to find a machinist local to you, at least get a quote.....
    A good thought, but I'd rather do it myself if possible.

  11. #11
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    Jun 2021
    Location
    Missouri
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    Quote Originally Posted by nadroj View Post
    Would it suit you to buy a used lathe, do your job and resell it?
    I hadn't thought of that. Not a bad option. Thanks for the idea.

  12. #12
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    Jun 2021
    Location
    Missouri
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    Quote Originally Posted by jack620 View Post
    Could you improvise something with a Dremel? Like in the picture, only with a hole for the aluminium rod to pass through at 90 degrees to the Dremel bit.
    I had considered something like this, but my concern ends up being how to get a respectably even groove all the way around when the rod itself is not turning. The jig would help with alignment, but then you have to think about minutely turning the rod over and over again. It may end up being the best option, but want to see what other ideas come up first. Thanks for weighing in.

  13. #13
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    Jun 2021
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    Missouri
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    Quote Originally Posted by pippin88 View Post
    O rings require a properly sized groove with an appropriate finish. If you are doing this for a hydraulic piston then I don't think you can do it without a lathe (or using a mill as a lathe)

    If it was purely decorative, then sure whatever.
    I'm not sure I understand why you couldn't get an appropriate finish this way. Couldn't you just polish the milled piece afterwards to get the finish as fine as you wanted? Serious question, not rhetorical.

  14. #14
    Join Date
    Dec 2007
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    Sydney
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    After cutting the groove it could be polished by using abrasive cord.
    Much easier to get someone with a lathe to do it for you.
    H.
    Jimcracks for the rich and/or wealthy. (aka GKB '88)

  15. #15
    Join Date
    Oct 2004
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    Southern Highlands NSW
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    I don't think an abrasive cord could be used, because the O-ring groove should be something like rectangular in section, not round.

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