A band saw with a metal cutting blade was easy and accurate. I would highly recommend it.
Bandsaw - I created a jig:
Very cool but like they say: don?t let perfection be in the way of completion
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.
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.
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.
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!
Since they are so thin, I just knocked them down 100% of the way with the medium-duty scotch brite wheel. It took a little while but it worked perfectly.
OK Here are links to 4 photos.
https://www.snapfish.com/library/share?via=link&token=K0BoVGUBFGSHUpB8hHM17A/AUS/27950480797070/SNAPFISH
https://www.snapfish.com/library/share?via=link&token=K0BoVGUBFGSHUpB8hHM17A/AUS/27950480457070/SNAPFISH
https://www.snapfish.com/library/share?via=link&token=K0BoVGUBFGSHUpB8hHM17A/AUS/27950479496070/SNAPFISH
https://www.snapfish.com/library/share?via=link&token=K0BoVGUBFGSHUpB8hHM17A/AUS/27950480929070/SNAPFISH
This method ensures fast, clean & accurate cutting of all angles.
Charlie