1. #1
    I'm after a reasonably priced ball nose mill suitable for cutting foam with a cutting length of at least 175mm in the UK

    The only ones I have found are the tools from Frog from the US


    Anyone know any good sources in the UK?


  2. #2
    Thanks chip,

    Those cutters are close, but still about half the length I need, have enquired on the custom option...

    I have searched for that thread, but can't seem to see it, can anyone point me to it?

    Last edited by jamezwarner; 04-05-2012 at 01:34 PM.

  3. #3
    I remember seeing some on eBay some time ago...

    What diameter do you need? Perhaps extending an existing cutter is an option. When I needed a long 1/2" ballnose cutter for MDF I just used a cheap router cutter with a 1/4" shank and made an extension with it using 12mm steel bar. Then hardened it for good measure. I chose 12mm steel bar as being a slightly lower diameter than the cutter the extension cannot interfere with what you're cutting.
    Old router build log here. New router build log here. Lathe build log here.
    Electric motorbike project here.

  4. #4
    I use long 6mm or 8mm twist drills reground (by eye/hand) to a round end. Works for me.

    Alan D.

  5. #5
    High Density Foam? Best result I had was with a Burr bit :s or maybe I just got the whole spindle speed/feed rate wrong :)

  6. #6
    Aha, spindle speed? I don't know - I use a cheap 240volt router run at 100volts. It lasts for ever in that mode. A slow(ish) speed sometimes helps prevent the foam sticking to the bit with heat if you are cutting deep. That varies with the foam density and composition, of course.

    Alan D.

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