Cutting Rudder Stiffeners

[GPV]

Originally Posted by tyconnell

Bandsaw - I created a jig:

I like it! Will have to try something similar.

[tyconnell]

Originally Posted by control

Very cool but like they say: don?t let perfection be in the way of completion

Definitely guilty of that. Sometimes, though, you just gotta play with your tools man!

[506DC]

Mark the cut, use tin snips from each end to the center then bend the
piece to break off the center part. Shape the end with a disk sander
and debur with 3M finish sander.

I drilled another hole between the end rivets to prevent cracking on the elevators and rudder.

[gasman]

Originally Posted by 506DC

Mark the cut, use tin snips from each end to the center then bend the
piece to break off the center part. Shape the end with a disk sander
and debur with 3M finish sander.

I drilled another hole between the end rivets to prevent cracking on the elevators and rudder.

Learn to use your hand tools..... They will save you a lot of time and money. By the time you set up a jig, the parts can be done.

When using a band saw, lower the blade guide down close to the part for safety and accuracy,

[bjdecker]

I used the shear portion of my 30" Harbor Freight combination shear/brake/roll to cut the stiffener angles, and then the 3M scotch bright wheel to debur

Cheers!

[GeoffP]

Originally Posted by bjdecker

I used the shear portion of my 30" Harbor Freight combination shear/brake/roll to cut the stiffener angles, and then the 3M scotch bright wheel to debur

Cheers!

I used a hand shear then deburred on a 6" scotchbrite wheel. Shear gives a nice clean cut straight up. I think it took longer to remove the vinyl than to cut & deburr each piece.

[n982sx]

Originally Posted by GeoffP

I used a hand shear then deburred on a 6" scotchbrite wheel. Shear gives a nice clean cut straight up. I think it took longer to remove the vinyl than to cut & deburr each piece.

+1 on the hand shear (like these http://aircraftproducts.wicksaircraf...ion-snips/mc14) not tin snips. You can do all of the stiffeners with a hand shear and deburr on the scotchbrite wheel before you get the band saw set up.

[FloMo14Builder]

I have the Andy Snips, band saw with metal cutting blade, 1" HF belt sander, and the 6" scotch bright wheels. Based on my extensive (practice kit) experience I have found a quick rough hand cut on the band saw or snips (currently have no preference) followed by 10 seconds on the belt sander gets me ready for deburring on the bench grinder. If my bandsaw wasn't a permanent fixure, then I would deffinately just stick with the snips.

[Ender]

Originally Posted by tyconnell

Bandsaw - I created a jig:


I believe the clamp attached to the board is a toggle clamp.

I rounded the corners after cutting using the disc sander portion of a desktop belt sander, and finished with a Dremel 500 wheel. For flimsy parts like the stiffeners, I prefer this smaller wheel to the scotch brite wheel.

OH man, I remember when I was trying to do that. +1 on the don't let perfection slow you up. Or better yet, when it's not perfect, feel comfortable to move on. The parts in my "corner of shame" for my tail were way too numerous; most of them would be been just fine, but I was being a perfectionist.

[chaskuss]

Originally Posted by bjdecker

I used the shear portion of my 30" Harbor Freight combination shear/brake/roll to cut the stiffener angles, and then the 3M scotch bright wheel to debur

Cheers!

I did something similar. My RV guru, Jody Edwards, told me to use a paper shear to cut them. I took a few pieces of scrap wood, hot glued the wood to the paper shear. The wood aligns the stiffeners to the proper angle. This way, you only have to set up the angle once.
This temporary jig, made this job quick, easy and fast. Greg, I'll email you a photo or two of this set up to night when I get home. I'll try to host the photos somewhere and add them to this post later.
The hot glue will hold the wood, yet allow you to easily remove the wooden guides when you are done.

OK Here are links to 4 photos.

https://www.snapfish.com/library/sha...97070/SNAPFISH

https://www.snapfish.com/library/sha...57070/SNAPFISH

https://www.snapfish.com/library/sha...96070/SNAPFISH

https://www.snapfish.com/library/sha...29070/SNAPFISH

This method ensures fast, clean & accurate cutting of all angles.

Charlie