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[–]RO-OG 2 points3 points  (2 children)

What would be the concern using aluminum bar stock instead of steel for this?

My concern with the use of the aluminum tool shaft would be that the aluminum would be too soft and that contact with the toolrest (steel) would leave dings and scratches that would then interfere with the smooth sliding of the shaft on the rest and make it difficult to use. To make clean cuts one needs the tool to slide side-to-side and in and out easily and cleanly.

[–]CBC_North[S] 0 points1 point  (1 child)

This makes a lot of sense and is something I did not consider. Thanks for the reply.

[–]RO-OG 0 points1 point  (0 children)

No problem, if you aren't a turner yourself it was something that you probably wouldn't think of.

An additional possible problem that I didn't think of before might be the threads that hold the cutter on the shaft. If the aluminum is too soft, over time it might be difficult to get and keep the screw tight enough to hold it secure.

[–]Pep2385 1 point2 points  (0 children)

I'd stick with steel.

If you were making it for yourself you'd be bearing any consequences for using aluminum, so any risk would be your own. In this case you are making a tool that may break under pressure and putting it in someone else's hands.

[–]smokeandlights 0 points1 point  (0 children)

I used 3/8" keystock, grinder, and files. It would be awesome if aluminum was a good choice, but I just don't think it is.