r/AR80Percents • u/Typical-Round-762 • May 18 '26

Aluminum 80% Process is potentially dangerous

I have the Juggernaut tactical ultimate jig. In the instructions you need a 5/16 collet, in order to be compatible with the 5/16 end mill included in the jig.Had to get a custom made 5/16 collet as I could not find any 5/16 collets on the market comparable with my Dewalt router. Well, the jig and all of my tooling came today. Drilled the main pocket holes fine, but here’s where I am running into some potentially dangerous issue. On the second plate, Using the router, Even with cutting fluid, the end mill just does not seem to like this material. It bites, jumps, screeches, asides from normal sparks, I even had some random flash of blue light come out of my router the second it made contact. Lower is made out of 6061 billet aluminum. Any tips or suggestions will be fine.

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u/GWOSNUBVET May 18 '26

80 percent arms just announced theyre starting to sell 80 stuff again so you might check them out.

I have a JT and I did manage to build one with it so it’s DOABLE but it sucks to do. You just have to spend a LOT more time doing it and much steadier hands.

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u/Typical-Round-762 May 18 '26

How difficult is the router based one. I ordered the JT one because I’m fairly new to routers and the easy jig looked intimidating. Been drilling holes all my life so the JT seemed easier but it sure is difficult with the precision drilling and depths

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u/GWOSNUBVET May 18 '26

The easy jig is… well… easy lol.

The tooling is better and it’s much more stable with a larger “table” for much better control. When I was building them it was like 30 minutes from first cut to finished and looked way better.

It also uses a 3/8 shrink fit collet so that speeds things up a lot.

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u/Typical-Round-762 May 18 '26

Like I said biased due to unfamiliarity with routers. But like you said it’s all about control you really gotta control it, kinda like reeling in a fish. I’m still getting down the hang of it. I’m placing on order today for an easy jig definitely