Hey guys,
I am a long time viewer of cnczone, and finally I need some help on something Im having a lot of time caught up in. Heres the deal.
We are engineering the manufacturing line for a new business, and i have run into a problem that isnt all that typical of an operation to my knowledge.
I need a router bit that is mounted in a porter cable 1_3/4 hp router within a special jig setup. The bit needs to be exactly 3/4 o/d straight plunge by 3/4+ cut height with a 1/2 shank. It also needs to leave a flat cut in the material on the bottom of the plunge. I am using this as a straight plunge directly vertical into the material, ie there is no shear or climbing of the cut. An example of this would be to put the bit into a drill press and plunge a hole into the material (im using it like you would in a drill, to make a 3/4 hole). It CANNOT leave any type of nipple facing outwards at the bottom of the plunge, like most bits would.
I have contacted Amana Tool (which I have spent an arm and a leg on router bits with) and they arent very helpful. After a few tries and suggesttions they recommended their super plunge bit (part number 41438). The problem with this bit is it also leaves a nipple on the material, and doesnt cut worth a **** (the dimensions are correct but the bit just wont cut). I am milling end-grain, quite hard gunstock type plywood. The router has enough power and doesnt bog down so the 1_3/4 hp isnt a problem.
I need something that will make a clean plunge and also doesnt smoke and start my shop on fire. The bits that I have been recommended cannot even bore softwoods without almost starting on fire. I dont care what type of bit it is as long as it cuts a flat bottom, cuts without smoking on the first 1/16th inch of a brand new bit, and can handle some manufacture type usage. Cost is not a big deal as long as its not custom made. It has to fit in a high speed router, ie, no forester bits or anything like that.
Thanks a lot,
cf