Flange Removal from casting

[jap]

What method do most people use to machine the flange off the casting? A Dremel? A Router? A Saw? In my application, my parts must join flatly where the flange is removed. Imagine a hatch cover, and that’s essentially the part.

When I use a dremel, my cuts are inconsistent. A router requires a jig, and my first design also made inconsistent, (damaging), cuts. ( Both are SLOW!!! )

I’m considering using a table saw in a two step process to: 1) Cut the flanges down perpendicular to the part’s base near the finished part to make them even and manageable, and 2) a jig which cuts them parallel to the part’s base at the proper height (H). (Pardon my sloppy scribble!)

What do you think?

[Worldwealth]

What method do most people use to machine the flange off the casting? A Dremel? A Router? A Saw? In my application, my parts must join flatly where the flange is removed. Imagine a hatch cover, and that’s essentially the part.

When I use a dremel, my cuts are inconsistent. A router requires a jig, and my first design also made inconsistent, (damaging), cuts. ( Both are SLOW!!! )

I’m considering using a table saw in a two step process to: 1) Cut the flanges down perpendicular to the part’s base near the finished part to make them even and manageable, and 2) a jig which cuts them parallel to the part’s base at the proper height (H). (Pardon my sloppy scribble!)

What do you think?

Creative trimming is key to each new designed part. I would believe all of us think these steps through carefully if they don’t mirror a previous project.
Your on the right path with your thinking. Trial and error teach us everything in these situations.
One rule of thumb I always use is, “What is the safest,fastest most cost effective trim ?”.
I fabricate several flat,round profiles to do the final finesse sanding to get perfect edges prior to any UV clearcoating.

[JMS11729]

Looks to me like a flush trim router bit would be the ticket in this case?