Does anyone have a good way to cut the aluminum sheet so you don't get the sheer marks and ripples?

Views: 559

Reply to This

Replies to This Discussion

Dan,

Look for previous posts for an Olfa knife.

You scribe along a straight edge and then can bend sheet back and forth till it separates along scribe line. 

Clean up edge with files, sand paper etc and you are done.

Works very good in many applications.

A super tool and not expensive.

I agree with Jerold, the Olfa is the way to go.  It does a beautiful job. It is a high quality scribing knife designed for cutting tile. Here is a link to a discussion on using the Olfa --- http://www.ch601.org/tools/olfa.htm

Tim

Not all tin snips (hand shears) are created equal (some are better quality than others). Also it helps to not make such large cutting motions; take small bites and keep the shearing action in closer to the pivot of the shear. Distortion seems to more pronounced out near the tips (points) of the hand shear. Also it is best to first cut about 1/4” outside of the desired cut and then go back and trim the remainder off.

There is nothing like having a foot shear, though.

Good luck,

Joe

The Olfa P-800 is commonly used to cut aluminum sheet. 

Use a straight edge.

Score Score Score Score ...

Bend at score mark.


I couldn't find a specific video showing it. Although I know I've seen one. However, here's a link to a guy talking about the concept that might help if you've never seen someone do it. Although, the Olfa P-800 knife works great and I would see little if any need for improvement for a hobby/project build type environment.

https://www.youtube.com/watch?v=lAYtbHxjECg

No ripples with this method. Easy edge clean up. Best method IMHO for a home type shop. Maybe one downside is that this doesn't work unless the sheet is well back (i.e. on table, etc.). 

Also, while aviation snips and similar do tend to leave ripples, with a little practice these can be minimized or effectively eliminated. Angling the cutting edge helps. Doing a rough pass and leaving a 1/8" or so will help build up confidence/techniques. I always leave a 1/16" to 1/32" edge to file away if I have to use aviation snips. I've also found planing tools like the Surform to be work really well. Although a bit tricky on 0.016 if you're not careful.

Cheers,

Don

I used cheap long bladed scissors, using just the inside half. Cut beautifully. Recommended to me by an engineer who'd scratch built a 701. Was the first hint he gave me!

Pneumatic "air nibbler"... Best.....Tool.......EVER!!!! 

Buy the videos from www.homebuildhelp.com.  "Metalworking 101" and  "Scratch building basics for metal aircraft" will be the answer to most if not all of your questions.

RSS

New from Zenith:

Zenith Planes For Sale 
 

Classified listing for buying or selling your Zenith building or flying related stuff...

                                                     

Weather Maps


Custom Instrument Panels
for your Zenith
:

Custom instrument panels are now available directly from Zenith Aircraft Company exclusively for Zenith builders and owners. Pre-cut panel, power distribution panel, Approach Fast Stack harnesses, Dynon and Garmin avionics, and more.


Custom Upholstery Kits for your Zenith Aircraft:

Zenith Vinyl Upholstery Kits


Zenith Apparel from EAA:


Zenair Floats


Flying On Your Own Wings:
A Complete Guide to Understanding Light Airplane Design, by Chris Heintz


Builder & Pilot Supplies:

How to videos from HomebuiltHELP.com

Developed specifically for Zenith builders (by a builder) these videos on DVD are a great help in building your own kit plane by providing practical hands-on construction information. Visit HomebuiltHelp.com for the latest DVD titles.

Aircraft Insurance:

 
 

West Coast USA:

Transition Training:

Pro Builder Assistance
 

Pro Builder Assistance

Aircraft Spruce & Specialty for all your building and pilot supplies!

© 2019   Created by Zenith.Aero.   Powered by

Badges  |  Report an Issue  |  Terms of Service