Fast and clean way to cut out ribs, and assorted parts

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Comment by Robert Pelland on June 14, 2010 at 8:38pm
Good evening Robert,

The box was actually out of necessity because of the work area. The garage is full of collector cars, ( ) so I had to set up an additionnel workshop in the basemant, along with doubles of all the power tools. This created a problem since the floors are covered with deep pile carpet. To try and keep as much shavings off the carpet as I could, I can up with the idea of the box. Trouble is, it was all in vain, because after a few years, there is now enough aluminumm shavings stuck in the carpet ( they can't be sweept, of vacumed ) to make a complete 4' by 12' sheet of aluminum :o(

Good luck with your build
Comment by Robert Crawford on June 14, 2010 at 8:18pm
Hi Robert,
Champ did mention that he got the idea from you for the elevator hinge doubler, just wish I hadn't already closed the piece up when he sent me the e-mail. I would have done mine from the inside as you did. Also, I had thought about making a box similar to the one you use for routing your ribs, oh well, maybe when I build another one I won't have as big a mess to clean up!!!
Comment by Chumphol Sirinavin on February 9, 2009 at 3:25pm

I have bought a router for months, but had no idea how to use it for wing rib building, and had to hand file each of the rib blank bolted between form blocks. Thanks for your video showing cutting block, and all.

Comment by Zenith.Aero on February 2, 2009 at 9:42am
Great video! Thanks for making it and sharing it!
Comment by Robert Pelland on February 1, 2009 at 9:37am
Tim, I have tried an assortement of different bit's, and what proved to be the best were the bearing flush " edge trimming bit's " They are available in different sizes, but what ended up being the very best choice, were the larger 1/2" shank models. The one that is on the router now is from "Freud" in the 1/2" x 1/2" size, and has cut many, many hunderds of parts, and other then a little paint flaking on the shaft, it shows absolutuly no wear what so ever. I tried the small 1/4" shank bit's, but they didn't hold up to the heat, and wear that is seen when cutting aluminum.

I also strongly recommend that you cut only one part at a time. The reason is because when you cut multiples, the high heat that is generated, tends to weld the edges together and makes a mess of the edges when you remove them from the cutting blocks.. All in all, there is no faster, or cleaner way to cut out the parts when scratch building then using a router. In my video " router " you will notice that I used a home made cutting box that not only make the cutting block's easier to manage, but it also contains more then 99 % of the shavings.

Robert the 701 & 750 Scratch
Comment by Tim Garrett on February 1, 2009 at 8:28am
You might add what bit you are using in the router?

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