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