I have a roof rack that uses 8020 Extrusion Bars as crossbars on factory roof rails. I have previously made risers for it out of seaboard using my MPCNC. They were actually my very first project other than some drawings. With that said on roof rails the cross members weren’t even so I couldn’t lay things flat on them if I needed to. To remedy that I finally was able to cut my first aluminum by putting in slots on one side of the member that will allow me to adjust vertically the height of the cross bar. Had to also design a jig to hold the piece correctly. Was a pretty fun project to locate everything.
Cutter: 1/8" Single Flute upcut from V1 (worked perfectly)
Speeds: 1000 mm / min
DOC: 0.5mm (could have probably have done 1mm)