Lead counterbalance weight for Ailerons
Posted: Sat Jan 29, 2022 9:54 am
by Pmm2
Hi,
I am new to aircraft building and just starting my wings, the shipping company damaged the two pre-built forward spars and leading edge skins, so for now I am building what I can while waiting for new spars and skins so I am putting the Ailerons together. I have to cut the one 1" thick rectangle shaped lead weight into two equal sized/shaped weights. There does not appear to be much room for error. What is the best method for cutting the lead? I have your normal shop tools but have never had to precisely cut lead before. Thank you in advance.
Pat
SNB-0031
Re: Lead counterbalance weight for Ailerons
Posted: Sat Jan 29, 2022 10:17 am
by Scott Todd
I used a band saw with a regular coarse wood blade in it. Go slow and it works fine. I don’t know about the full size ailerons but on my Onex, the weights were WAY too much and I ended up cutting them down more and drilling holes in them to get the ailerons to balance after paint.
Re: Lead counterbalance weight for Ailerons
Posted: Sat Jan 29, 2022 10:34 am
by Mike53
I used my table saw with 80 tooth carbide blade . Cut very slowly .
Re: Lead counterbalance weight for Ailerons
Posted: Sat Jan 29, 2022 2:10 pm
by Bryan Cotton
Bandsaw here. Worked fine.
Re: Lead counterbalance weight for Ailerons
Posted: Sun Jan 30, 2022 9:03 am
by Pmm2
Thank you for your replies. I have several options. I will need a different blade for my bandsaw or use a table jig saw with a wood blade. My Dad bought it years ago, used it once. I got it from him several years ago but never used it. Looks like a good choice for dust collector tool I thought I would never use!
Pat
Re: Lead counterbalance weight for Ailerons
Posted: Sun Jan 30, 2022 12:14 pm
by Area 51%
Not much dust gets thrown up when cutting lead.
Re: Lead counterbalance weight for Ailerons
Posted: Sun Jan 30, 2022 3:53 pm
by pfhoeycfi
Old school hack saw. Very easy.
Peter
Re: Lead counterbalance weight for Ailerons
Posted: Mon Jan 31, 2022 10:46 am
by builderflyer
Cut lead, band saw, hack saw??? Thats all? In the previous century, we Sonex builders bought lead from whatever source such as fishing weights, melted it down on a Coleman camp stove and poured it into homebrew wood forms to create a rough casting. Then filed it down to final size, shape and weight.. You latecomers have it way too easy.
Art,Sonex taildragger #95,Jabiru 3300 #261
Re: Lead counterbalance weight for Ailerons
Posted: Mon Jan 31, 2022 11:21 am
by DCASonex
Pmm2 wrote:Thank you for your replies. I have several options. I will need a different blade for my bandsaw or use a table jig saw with a wood blade. My Dad bought it years ago, used it once. I got it from him several years ago but never used it. Looks like a good choice for dust collector tool I thought I would never use!
Pat
I would avoid the jigsaw for this, lead builds up in the cut if not continuously cleared as a band saw does. Also a hack saw would have long enough stroke if lifted clear for return.
David A.
Re: Lead counterbalance weight for Ailerons
Posted: Mon Jan 31, 2022 1:06 pm
by Rick524
LOL, Art, you bring back memories of when I made my lead weights…melting lead from scrapped
communications cables, in a coffee can on my backyard firepit and pouring it into wooden forms…good times!
Rick
Sonex 524
Re: Lead counterbalance weight for Ailerons
Posted: Fri Feb 11, 2022 4:54 pm
by Stevetin
I bought a 12" non-ferrous metal cutting blade for my compound miter saw. I cut the lead block as well as most of my aluminum angles with it. The cuts were easy, accurate and very smooth with little need to file or deburr.
Steve