So, cut the first (left) elevator control surface perfectly, but when I got to the other one, the saw bound up real nasty and jerked the part real bad. Tried to save what I could but I’m not proud of the part, its edge is not straight and it’s 5mm shorter than the other side. Is this salvageable at all or is this aluminum stock just scrap now?
That’s a good question for Sonex. You can probably save it, the question is do you want to. I’d make that cut with snips and clean up the edge with files and scotch brite. Don’t rush to the power tools for everything.
We all have a collection of scrap parts and the elevator is a better part to learn on than a wing skin.
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I think, since I still have some stock left over for the rudder, I’ll scrap this one, order another xenos control surface stock, and make a second pass at this part using the aluminum shears instead. Thanks for the help!
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Hi Fake,
That’s a common mistake/problem. I know others (me) who have done the same thing.
I seem to always have some Styrofoam laying around. I solved the problem by pressing the control surface end I was going to cut into a piece of Styrofoam to make an outline of the part. Then I cut out the pattern (slightly oversized) and insert it into the end of control surface to support it while I made the cut with a band saw. YMMV.
Wes
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