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How to create a strong join in aluminium t-slot extrusion

We understand that you need to save time and money.  So we would like to show you the most cost effective way to join extruded aluminium t-slot profile. 

Aluminium T Slot extrusion joint

This is the standard joining method for Alusic Aluminium profile and is surprisingly quick and easy.  In less than 60 seconds one can make a strong join between aluminium t-slot extrusions at minimal cost.  There is no complicated machining involved.  There are no special tools required.  This can be done on site without welding or the need for a hot work permit.  

Follow this step by step guide to learn how.

** For your own safety sake, please ensure that you follow all relevant safety procedures and guidelines when operating machinery and using power tools. **

Drop saw for cutting T Slot aluminium profile extrusions

1. Cut your profile to length.

It is important to make a clean accurate cut because this will impact the quality of your finished join.  Use a good quality saw with the correct type of blade for cutting aluminium.  A good supply of quality cutting fluid will be needed to prevent profile and blade overheating.  Make sure that your profile piece is securely clamped.  To save you time we are able to cut your aluminium profile to length for you.  You simply need to provide us with a cut list. 

T slot Aluminium extrusion drill and tap

2. Tap the core hole in the end to be joined.

This is a very simple and quick process as the core is perfectly formed to the correct size for tapping.  Use an M8 tap for slot 8 series, or M6 for slot 6 series, profiles.  Using an extrusion tap and the correct cutting paste will ensure a perfect thread will be formed.

Alusic T Slot Aluminium drill jig

3. Drill an access hole for your hex key.

Use a drill press, or drill guide, to accurately position the hole and not damage the profile piece.  We generally use a drill press specially set up for this job.  The drill guide is only really useful for when you don’t have a drill press or when you’re on site needing to drill a hole.  

T slot aluminium cap screw and washer for junction

4. Fit a low profile cap screw and square washer to the hole you tapped earlier.

All of these parts are available from our online store.

Aluminium profile parts and accessories  for a secure connection.

5. Slide the washer and cap screw head into the slot.

Move it into the slot so that the cap screw lines up with the hole drilled earlier.

Alusic T Slot Aluminium Profile joining system

6. Using the access hole you drilled earlier tighten the cap screw with your hex key.

Make sure that the two sections of t-slot are perfectly aligned as you tighten up the join.

You have now created a strong join in aluminium t-slot extrusion.

There are several alternative methods of joining Alusic t-slot aluminium profiles.  These alternative methods are useful under different circumstances.  If you would like more information please check out our blog.  We have articles about through body joins and joins using clamping plates and pawl clamps.  You can also view these informative videos showing some of the more common connection systems. 

You can also find lots of useful accessories to help provide you with a large range of  options at our web store.

Accessories for extruded T slot Aluminium Profile

To help you get the most out of using Alusic T Slot Aluminium extrusions and accessories we have made all the resources we could find available on our website for you to download.

  

T Slot Aluminium Extrusions and accessories
GAP Engineering T Slot Aluminium Extrusions and accessories