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Is there a trick to cleaning up a new cut aluminum edge?

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AZFlyer

Joined: 11 Jan 2006
Posts: 89
Location: Prescott, AZ

Posted: Tue Apr 25, 2006 10:35 am Post subject: Is there a trick to cleaning up a new cut aluminum edge?

I have tried numerous methods to flatten and smooth edges on aluminum sheet I've cut.  Nothing yet has made them look professional.  I take my time cutting to produce minimum ridges and distortion but even after filing and sanding I can not get that pro-look.  



Somebody out there must know a secret.  Please share.  What is the trick?



Thanks,

Mike

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_________________
Mike Miller @ millrml@aol.com
601 XL-B, 3300, Dynon

Remember, "the second mouse gets the cheese"!

frank.hinde(at)hp.com
Guest

Posted: Tue Apr 25, 2006 11:06 am Post subject: Is there a trick to cleaning up a new cut aluminum edge?

Yes...but nobody knows what the trick is.... 



1) First thing to remember is that tin snips will stretch the edge of

the sheet if you try to cut too much off at once...So if you imagine a

freshly cut edge where the edge is longer than the rest of the sheet

then you will have a wavy edge.



To stop this, do not cut up to the edge on the first cut, rather stay

1/4 to 3/8ths away from where the finished edge will be on our first

cut.



Tha second cut you go up to the line and it will not be wavy.



2) Do not cut off the end of the snips....I.e do not close the snips all

the way otherwise you get a notch where the tips of the blades come

together.



3)Use a fine (ish) file to remove the snip marks



4) Use a red scotchbrite pad to remove the file marks



5) To automate steps 3 and 4 use a medium Scotchbrite wheel mounted in a

DECENT (not one that slows down with any pressure) bench grinder...Mine

is a 3/4HP arbor Freight PROFESSIONAL model...Bloody marvelous machine.

You get the wheel from Van's aircraft for $45 (ya spendy I know)...but

now I have one of those I don't know how I built the Zodiac without it!



6) the edge can be rounded (deburred really) slightly with either the

wheel or pad.



7) For sheets try bending the edge down slightly with seaming pliers,

wheel thingy or happing the edge with a hammer overhangine the edge of

your bench by 1/2"...This will hold the edge down tight with the rivets



Good luck



Frank

HDS 295 hours

RV7A almost finished



--

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agustafson(at)chartermi.n
Guest

Posted: Tue Apr 25, 2006 11:50 am Post subject: Is there a trick to cleaning up a new cut aluminum edge?

File then Scotchbrite!



 	  Quote: 	
		  > Is there a trick to cleaning up a new cut aluminum edge?

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Tim Juhl

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

Posted: Tue Apr 25, 2006 1:46 pm Post subject: Re: Is there a trick to cleaning up a new cut aluminum edge?

I try to avoid using snips when possible, preferring the method taught to me by David Barth of CanZac aviation.  It gives you a straight edge that looks like it has been cut with a shear.   Read about it at



http://www.ch601.org/tools/olfa.htm

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

hrs1(at)frontiernet.net
Guest

Posted: Tue Apr 25, 2006 5:30 pm Post subject: Is there a trick to cleaning up a new cut aluminum edge?

Mike . .  try a Jillson snipper.  No rough edges.  Robert Schoenberger 701

---

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clojan(at)sbcglobal.net
Guest

Posted: Tue Apr 25, 2006 6:03 pm Post subject: Is there a trick to cleaning up a new cut aluminum edge?

I used a knife sharpner. The plastic kind with the v-notch. About 3  passes and the edge is smooth and beveled. Jack in los osos ca.  Hope to fly friday. 



Jack Russell -Clovis CA

601 XL Jabiru 3300

 Progress update at:

http://www.geocities.com/clojan(at)sbcglobal.net/zodiacbarn.html

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