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Best way to cut .040 stock
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PFolbrecht(at)starkinvest
Guest

Posted: Tue Jan 10, 2006 9:39 pm Post subject: Best way to cut .040 stock



Was making the 909 (?) shims for the HS.

Snips are not precise enough for stock this thick.

Die grinder with a cutoff wheel worked Ok, but spun badly a couple times. I

did one this way and one with the good 'ole hacksaw. Which might be the best

method.

I think these parts are too small for a bandway as well even if I had one that

cuts Al well, which I don't.

Just wondering if there were any suggestions for future parts of this type.

do not archive

Michael Wynn

Joined: 10 Jan 2006
Posts: 148
Location: San Ramon, CA

Posted: Tue Jan 10, 2006 9:47 pm Post subject: Best way to cut .040 stock



I experimented with a couple of different things. For flat stock, a

non-ferrous blade in a table saw makes really nice, straight, smooth cuts. If the

stock is irregular or bent, be really careful. I got a nice kickback that sliced

up a hand pretty well. I have also used a band saw with a metal cutting

blade. That works great but you need to set up a fence to keep the cuts straight.

Regards,

Michael Wynn

RV-8, Wings

San Ramon, California

Do Not Archive

_________________
Michael Wynn
RV 8
San Ramon, CA

bicyclop(at)pacbell.net
Guest

Posted: Tue Jan 10, 2006 10:35 pm Post subject: Best way to cut .040 stock

diesel(at)rconnect.com
Guest

Posted: Tue Jan 10, 2006 11:25 pm Post subject: Best way to cut .040 stock



Subject: Re: Best way to cut .040 stock

I cut from .020" to .125" aluminum sheet as well as aluminum angle stock to

.250 " using a band saw with a fine tooth plywood veneer blade. A power

hacksaw worked also but the aluminum is soft enough that the veneer blade

cut faster and actually better so I stopped using it in favor of the

bandsaw. The cut is then finished with a small belt sander to remove the

blade marks and polished smooth with a scotchbrite wheel.

Dick DeCramer

N500DD RV6

100hours

N149KC RV4

Northfield, MN

jjessen(at)rcn.com
Guest

Posted: Wed Jan 11, 2006 9:29 am Post subject: Best way to cut .040 stock



If you're not cutting a whole lot, I've used a Dremel with a cut off wheel

and found it not only fast but accurate. The other route is to make a zero

tolerance insert for your band saw so the material doesn't get sucked down

and stays nice and firm on the table. Make sure, however, that your band

saw blade is many teethed and that you tune it up so the blade doesn't

wander, ruining your cut. Works fine that way for most thicknesses.

John Jessen

RV-10 elevators.

dan(at)rvproject.com
Guest

Posted: Wed Jan 11, 2006 9:57 am Post subject: Best way to cut .040 stock



Is it just me, or has nobody mentioned using a SHEAR yet?

do not archive

) ( Dan

RV-7 N714D

http://www.rvproject.com

-

cjensen(at)dts9000.com
Guest

Posted: Wed Jan 11, 2006 10:55 am Post subject: Best way to cut .040 stock



A shear? That's cheating---that'd be too easy.

Chuck Jensen

gerf(at)gerf.com
Guest

Posted: Wed Jan 11, 2006 11:26 am Post subject: Best way to cut .040 stock



This is a case of SoCal bragging - those CNO guys 'n gals seem

to have every tool imaginable 

How about a plasma screwdriver for my EPS conduits ?

g

do not archive

[quote]

dan(at)rvproject.com
Guest

Posted: Wed Jan 11, 2006 12:01 pm Post subject: Best way to cut .040 stock



 	  Quote: 	
		   This is a case of SoCal bragging - those CNO guys 'n gals seem

to have every tool imaginable 

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mark(at)macomb.com
Guest

Posted: Wed Jan 11, 2006 1:50 pm Post subject: Best way to cut .040 stock



My favorite: Klein makes a bottle opener with the rubber grip just like

their screwdrivers. Lowe's carries them.

Mark

Do not archive

Dan Checkoway wrote:

 	  Quote: 	
		  

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rv6fly(at)bresnan.net
Guest

Posted: Wed Jan 11, 2006 8:04 pm Post subject: Best way to cut .040 stock



Folbrecht, Paul wrote:

 	  Quote: 	
		  

Was making the 909 (?) shims for the HS.

Snips are not precise enough for stock this thick.

Die grinder with a cutoff wheel worked Ok, but spun badly a couple times. I

did one this way and one with the good 'ole hacksaw. Which might be the best

method.

I think these parts are too small for a bandway as well even if I had one that

cuts Al well, which I don't.

Just wondering if there were any suggestions for future parts of this type.

do not archive

Paul,

I used a Delta, 3 wheel band saw on several airplane projects, cutting

up to 1/4" aluminum. I used a regular wood blade with 14 TPI and LPS

"Tap-All" on the cut line. I think kerosene works well for cutting

aluminum if I remember correctly. With the use of cutting fluid, the

blades seemed to last forever. The saw is still going strong after use

on a Glasair, Glastar and several RV projects.

Bob Skinner Buffalo, WY

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bcollinsrv7a(at)comcast.n
Guest

Posted: Wed Jan 11, 2006 8:40 pm Post subject: Best way to cut .040 stock



 	  Quote: 	
		   >Snips are not precise enough for stock this thick.

	


Hmmm.. The way I learned about cutting was to drill the corners and use the

snips and cut it 1/8" off the actual line of the desired piece and then file

and Scotchbrite it down to its final shape and dimension.

Did I learn wrong?

Do not archive

HCRV6(at)comcast.net
Guest

Posted: Wed Jan 11, 2006 10:05 pm Post subject: Best way to cut .040 stock

I'm late jumping into this but FWIW I've found that the best way to cut any small sheet parts af any thickness is with an inexpensive band saw and the finest toothed (if that's a word) blade you can find.  14 works, and a wood cutting blade lasts almost as long as a metal cutting blade, at least in my $50 Craftsman band saw, one of the best investments in tools I made at the start of my project.



--Harry Crosby

RV-6 N16CX, 161 hours and down for painting.



 -------------- Original message ----------------------

From: "Bob Collins" <bcollinsrv7a(at)comcast.net>

 	  Quote: 	
		   

 

 > >Snips are not precise enough for stock this thick.

 

 

 Hmmm.. The way I learned about cutting was to drill the corners and use the

 snips and cut it 1/8" off the actual line of the desired piece and then file

 and Scotchbrite it down to its final shape and dimension. 

 

 Did I learn wrong?

 

 Do not archive

gerf(at)gerf.com
Guest

Posted: Wed Jan 11, 2006 10:20 pm Post subject: Best way to cut .040 stock

I M (not so) H O - snips suck !  They do a lousy job - they 

curl things up, they leave "jaggies" - that's why you have to 

leave 1/8" so you have enough room to clean up afterward.  

Definitely band saw - get as close as you can to your mark up 

lines without touching the line (takes concentration).  Finish 

up with the bench sander (if needed) and then the scotchbrite 

wheel.



g



 	  Quote: 	
		   

 

 

 > >Snips are not precise enough for stock this thick.

 

 

 Hmmm.. The way I learned about cutting was to drill the corners 

 and use the

 snips and cut it 1/8" off the actual line of the desired piece 

 and then file

 and Scotchbrite it down to its final shape and dimension. 

 

 Did I learn wrong?

 

 Do not archive

 

 

 

 

 

 

 

 

 

  

  

  

 

 

 

 


	


-- 

__g__



========================================================== 

Gerry Filby                                  gerf(at)gerf.com

                   Tel: 415 203 9177

aldaniels(at)fmtc.com
Guest

Posted: Wed Jan 11, 2006 10:33 pm Post subject: Best way to cut .040 stock

If you use I think it is just bar soap on the band saw or hack saw blade 

before cutting aluminum it reduces blade gumming. Most any wood cutting 

blades like a table saw, skill saw, or router with carbide tips is what 

many people that do a lot or heavy aluminum work use. I could not 

believe it the first time I saw someone go at a piece of 3 inch angle 

aluminum with a circular saw, but it works great.  Eye protection is 

essential as aluminum gets everywhere and the eye doc has a hard time 

getting it out. Someone correct me if it is not soap as I just am not 

sure I remember correctly.

HCRV6(at)comcast.net wrote:

 	  Quote: 	

I'm late jumping into this but FWIW I've found that the best way to cut any small sheet parts af any thickness is with an inexpensive band saw and the finest toothed (if that's a word) blade you can find.  14 works, and a wood cutting blade lasts almost as long as a metal cutting blade, at least in my $50 Craftsman band saw, one of the best investments in tools I made at the start of my project.

--Harry Crosby

RV-6 N16CX, 161 hours and down for painting.

 -------------- Original message ----------------------

From: "Bob Collins" <bcollinsrv7a(at)comcast.net>

>

>

>    

>

>>>Snips are not precise enough for stock this thick.

>>>        

>>>

>Hmmm.. The way I learned about cutting was to drill the corners and use the

>snips and cut it 1/8" off the actual line of the desired piece and then file

>and Scotchbrite it down to its final shape and dimension. 

>

>Did I learn wrong?

>

>Do not archive

>

> 

> 

> 

>

>    

>

Doug Gray

Joined: 10 Jan 2006
Posts: 112
Location: Sydney, Australia

Posted: Wed Jan 11, 2006 11:54 pm Post subject: Best way to cut .040 stock

I too have found the hand jig saw to work very well on .040 and up to 0.25.  I tape the stock to 

prevent the foot scratching the surface and find control excellent.  Easy to cut very close to the 

line.  I use a little Boelube on the blade before a cut.



On thinner stock I prefer the off cut wheel and die grinder.



I'd like to try a bandsaw but space does not permit.



Doug Gray

RV-6 Seat Back assy

PeterHunt1(at)aol.com wrote:

 	  Quote: 	
		   

 

 I had excellent success using a hand jig saw (DeWALT) and a fine blade and  

 moderate speed set on the trigger.  Straight cuts or curves come out really  

 nice if you have a steady hand.  I taped the stock to a table with the  portion 

 to be removed hanging over the table edge.  Cuts heavier stock just  as well.

Rick Galati

Joined: 10 Jan 2006
Posts: 91
Location: Lake St. Louis MO.

Posted: Thu Jan 12, 2006 5:09 am Post subject: Re: Best way to cut .040 stock

 	  PFolbrecht(at)starkinvest wrote: 	
		  

Was making the 909 (?) shims for the HS.

Snips are not precise enough for stock this thick.

Die grinder with a cutoff wheel worked......and one with the good 'ole hacksaw.............any suggestions for future parts of this type. do not archive 	




You seem to be covering most the bases. I too, dislike using hand snips, always found them to be more of a nuisance than anything else. By far the cleanest, most precise and efficient tool to use is a shear but for a variety of reasons, not many builders have ready access to one. Ours is so sharp, deburring the edge of the precision cut it produces is "almost" an option.  At home though, I simply use my bandsaw and dress the edge of the stock on a 12" bench sander fitted with 80 grit paper. If need be, the corners are then radiused and the edges polished on a bench grinder fitted with both medium and fine scotchbrite wheels. To prolong the life of my bandsaw blades, on thick stock such as .125 angle stock and thicker, I will use my chop (miter) saw fitted with a metal cutting blade but the cut it produces definitely requires touchup!  In summary, I would suggest your next major tool investment be a heavy 12" bench sander such as this good value...I have two of these, one is mounted on a pedestal stand at the hangar and the other one is sitting on a workbench at home...http://www.grizzly.com/products/G7297.  I think you'll quickly find its under appreciated utility and unexpected versatility will serve you well in a variety of situations for many years to come.  



Rick Galati  RV-6A  "Darla"

shempdowling2(at)earthlin
Guest

Posted: Thu Jan 12, 2006 8:32 am Post subject: Best way to cut .040 stock

I agree.



do not archive



Shemp/Jeff Dowling

RV-6A, N915JD

235 hours

Chicago/Louisville



---

deruiteraircraftservices(
Guest

Posted: Thu Jan 12, 2006 9:14 am Post subject: Best way to cut .040 stock

A hack saw. 24 or 32 T.P.I blade. TPI = teeth per inch.

sisson(at)consolidated.ne
Guest

Posted: Thu Jan 12, 2006 9:46 am Post subject: Best way to cut .040 stock

RAS wrote:



 	  Quote: 	
		  



A hack saw. 24 or 32 T.P.I blade. TPI = teeth per inch.



  



 
	




I used a pair of hand shears. They have about three or four inch cutting 

blades with  about 9 or 10 inch handles.

they are rusty and old but  fresh ground cutting edges. They cut 

straight, true, and easy. They leave no marks or metal deforming  like 

those "Wiss Aviation" snips do.  I guess they were old tinners shears. ( 

I think they are also Wiss)  I followed up with a fine file down each 

side for one or two strokes and it is smooth. I use them for 4130 steel 

also up to about 25 or 30 thousands.

Phil



do not archive

Phil

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