I need some input from fellow builders.  I'm plans building in order to stretch every dollar as far as I can.  That said, when I order materials for my spars I can obtain the extrusion angle (for top inboard spar angles) in 6061 but not in 1 1/2" x 1".  I can, get it in 2024 which Zenith's construction guide say is acceptable but the price is about $6.00/ ft more.

My thought is to cut 1 1/2" x 1 1/2" down to 1 1/2" x 1".  As long as I do not let any heat build up while band sawing and file / sand all marks out does anyone see a problems with this method.

Hate to sound cheap but this would save me about  $60.00.  Your comments will be appreciated.

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Tim, as long as you can cut it straight and make sure to dissipate the heat from the cut...i don't see any problems.

I use a plasma cnc on many of my cuts and there is no problem. As long as I pause between cuts and move the cutting head from place to place on my piece, all is good.

I even managed to cut .016 on my plasmacam.   By hand...you can control your speed and length of cut...so it should be fine.

My opinion

Tim,

I machine aluminum all the time and for cutting/tapping I use this;

 

http://www.grainger.com/Grainger/TAP-MAGIC-Cutting-Fluid-1MCU9?cm_m...

 

This stuff really great because it does 2 things at the same time. 1. it is a lubricant and 2. it evaporates and pulls away heat during the cut, better than just a cutting lubricant by itself. Because we are working with tempered aluminum heat is a concern. I use this regularly for CNC work and I spray the the blade of my band saw with it before cutting aluminum. If you have access to a metal cutting band saw that you can slow down the blade that would be even better, but even without that you will be fine with a good sharp blade. My band saw is down for repairs right now, I should have it running in a couple of weeks. You are welcome to come over and use it if you want since we are now that far apart.

 

Scott

 

Hey Scott, thanks for the tip and offer. I do have a band saw, will look into the lube though. Will give you a call...

Tim,

If you want the parts to look decent, don't even think of using a band saw.  There is too much lateral mouvement in the blade to make any clean cuts.  The parts however, could be sliced with a very professional look, by using a table saw with the proper guide.  It's much quicker, not to mention cleaner, and a lot less heat will be generated.  Use lots of lub, not on the blade ( it just flies off ) but on the full lenth of the aluminum part.

Ask me how I know !

 

Just my two cents

 

regards

Bob

Tim - Robert has a point about the table saw. But even with the bandsaw and filing out grooves your ok. I don't see any heat issues with either method. I milled mine on a milling machine; if you have access to a milling machine that's what I suggest.

Chris

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