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Best Tool For Doing Cutouts

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dvanlanen

Joined: 25 Jul 2006
Posts: 122
Location: Madison, WI

Posted: Thu Jan 10, 2008 5:55 pm Post subject: Best Tool For Doing Cutouts

What are other builders finding as the best tool for doing cutouts, such as access holes, trim tab cutouts, etc.?   I do not use the Wiss snips because they tend to stretch the metal.  I have an OLFA knife, which works great when cutting out flat stock, where the material can be backed up, but I can’t figure out how to safely use it on a structure where the material cannot easily be backed up.  I am currently using a Dremel tool with a cutting disk.  It works well but it is risky, as the cutting wheel can “catch” on the material.  This happened to me today, and put a slight abrasion on the skin – luckily it was not serious.  

Any advice would be appreciated, even if it means I gotta buy another tool.  

Thanks,  

Dave Van Lanen  

601XL - Elevator     [quote][b]

rjscep(at)yahoo.com
Guest

Posted: Thu Jan 10, 2008 7:32 pm Post subject: Best Tool For Doing Cutouts

 	  Quote: 	
		   I'm using a stepdrill to start the hole, then use

 aviation snips. If thats too tough, then use a 

 series of small holes with a drill bit close to the

 edge, then use a file to finish it....Do not archive

--- Dave VanLanen <davevanlanen(at)sbcglobal.net> wrote:
	




 	  Quote: 	
		   What are other builders finding as the best tool for

 doing cutouts, such as

 access holes, trim tab cutouts, etc.?   I do not use

 the Wiss snips because

 they tend to stretch the metal.  I have an OLFA

 knife, which works great

 when cutting out flat stock, where the material can

 be backed up, but I

 can't figure out how to safely use it on a structure

 where the material

 cannot easily be backed up.  I am currently using a

 Dremel tool with a

 cutting disk.  It works well but it is risky, as the

 cutting wheel can

 "catch" on the material.  This happened to me today,

 and put a slight

 abrasion on the skin - luckily it was not serious.

 

 Any advice would be appreciated, even if it means I

 gotta buy another tool.

 

 Thanks,

 Dave Van Lanen

 601XL - Elevator

 


	


Never miss a thing.  Make Yahoo your home page. 

http://www.yahoo.com/r/hs

sky_ranger161

Joined: 07 Jun 2006
Posts: 91

Posted: Fri Jan 11, 2008 4:08 am Post subject: Best Tool For Doing Cutouts

Hey!



Go to your favorite airplane parts store online and search for "hand nibblers." I got one for $20 from Avery Tools and wished Id discovered it two years ago. Great tool.



Debo Cox

Nags Head, NC

XL/Corvair

Wings 85% done

www.mykitlog.com/debo



do not archive



ROBERT SCEPPA <rjscep(at)yahoo.com> wrote:[quote] --> Zenith-List message posted by: ROBERT SCEPPA 



 	  Quote: 	
		   I'm using a stepdrill to start the hole, then use

 aviation snips. If thats too tough, then use a 

 series of small holes with a drill bit close to the

 edge, then use a file to finish it....Do not archive

--- Dave VanLanen  wrote:
	




[quote] What are other builders finding as the best tool for

 doing cutouts, such as

 access holes, trim tab cutouts, etc.?   I [quote][b]

dj45

Joined: 25 Jul 2006
Posts: 92
Location: Jackson MI

Posted: Fri Jan 11, 2008 6:31 am Post subject: Re: Best Tool For Doing Cutouts

Dave, I would suggest that you take a few pieces of scrap and practice some. I have used wiss snips for over 40 years and if done right, they don't stretch the metal. Use GOOD snips, not the cheap ones.

_________________
Do not archive

Dan Stanton
N801S CH 801
N226BS CH701
N24DS CH750

jmcburney(at)pobox.com
Guest

Posted: Fri Jan 11, 2008 7:47 am Post subject: Best Tool For Doing Cutouts

I found a Dremel attachment at Lowe's that made it a kind of junior Rotozip.

It works well, but BE CAREFUL!  Hold it tight when using, as it will want to

pull to one side.  You've got to show it who's master.  Cut slightly inside

the line, then use a Jilson cutter to trim, then finish with a file. I cut

my rear windows this way, on the plane, vertically, and had no (well, not

many) problems.



Jim



CH-801

DeltaHawk diesel

90% done 95% left

darrellhaas(at)gmail.com
Guest

Posted: Fri Jan 11, 2008 8:18 am Post subject: Best Tool For Doing Cutouts

OK, I also use a Dremel Tool but what is a Jilson Cutter?

Darrell



On 1/11/08, Jim McBurney <jmcburney(at)pobox.com> wrote:

 	  Quote: 	
		   



 I found a Dremel attachment at Lowe's that made it a kind of junior Rotozip.

 It works well, but BE CAREFUL!  Hold it tight when using, as it will want to

 pull to one side.  You've got to show it who's master.  Cut slightly inside

 the line, then use a Jilson cutter to trim, then finish with a file. I cut

 my rear windows this way, on the plane, vertically, and had no (well, not

 many) problems.



 Jim



 CH-801

 DeltaHawk diesel

 90% done 95% left

cgbrt(at)mondenet.com
Guest

Posted: Fri Jan 11, 2008 8:35 am Post subject: Best Tool For Doing Cutouts

Dave

 I use a step drill to to punch starter holes close  to the edges (3/4" to 1") . If it's a square panel four holes near the corners  then good right and left hand snips  with vertically offset handles to make  a rough cut to remove most of the panel. Folow with a final cut just short of  the line then finish with appropriate file and polish to finish the  edges.

 Carl

 [quote]   ---

dredmoody(at)cox.net
Guest

Posted: Fri Jan 11, 2008 8:51 am Post subject: Best Tool For Doing Cutouts

That's what you use to cut your Jilsons,



Dred

Do Not Archive



---- Darrell Haas <darrellhaas(at)gmail.com> wrote: 

 	  Quote: 	
		   

 

 OK, I also use a Dremel Tool but what is a Jilson Cutter?

 Darrell

 

 On 1/11/08, Jim McBurney <jmcburney(at)pobox.com> wrote:

 > 

 >

 > I found a Dremel attachment at Lowe's that made it a kind of junior Rotozip.

 > It works well, but BE CAREFUL!  Hold it tight when using, as it will want to

 > pull to one side.  You've got to show it who's master.  Cut slightly inside

 > the line, then use a Jilson cutter to trim, then finish with a file. I cut

 > my rear windows this way, on the plane, vertically, and had no (well, not

 > many) problems.

 >

 > Jim

 >

 > CH-801

 > DeltaHawk diesel

 > 90% done 95% left

 >

 >

 >

 >

 >

 >

Tim Juhl

Joined: 21 Mar 2006
Posts: 488
Location: "Thumb" of Michigan

Posted: Fri Jan 11, 2008 1:05 pm Post subject: Re: Best Tool For Doing Cutouts

I would avoid power cutters unless you are using them just for rough cuts. You really don't want to screw up those 12 foot wing skins and the like.  I bought a power nibbler that you insert in a drill but found it too hard to control when making fine cuts.  I use it for rough cuts and then finish with a hand tool.



For inspection holes I use a fly cutter (turned by hand) for the round holes and an olfa knife to score the lines between them.  Drill a large hole in the waste with a step drill and then use shears, nibblers or whatever to cut the part you're removing into sections that can be wiggled to break along the scored lines.  A good selection of files will be helpful in any case. 



Regarding backing up the material being scored - I have at times cut some specific backup pieces out of scrap wood.   For example, a wedge to go inside a control surface where I am cutting out a section for a trim tab.  I also have a couple of flat pieces with holes drilled to match the shaft of the flycutter which have been very useful in doing inspection holes.



Tim

_________________
______________
CFII
Champ L16A flying
Zodiac XL - Jabiru 3300A
Almost done! It'll fly in spring!

mhilderbrand

Joined: 28 Sep 2006
Posts: 36

Posted: Fri Jan 11, 2008 1:58 pm Post subject: Best Tool For Doing Cutouts

Got my hand nibbler from Radio Shack for around $6 

 

Michael Hilderbrand

Derby, Kansas

Http://www.kansasflying.com 



 ---

gary(at)liming.org
Guest

Posted: Fri Jan 11, 2008 2:33 pm Post subject: Best Tool For Doing Cutouts

At 10:17 AM 1/11/2008, you wrote:

 	  Quote: 	
		  



OK, I also use a Dremel Tool but what is a Jilson Cutter?

Darrell


	


If you go to www.liming.org/ch801/tools,html



there is a picture of a Jilson tool about halfway down.  (actually it 

is a picture of a Harbor Freight cheap clone of a Jilson tool.)



Gary L.

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