A quick way to make repetative parts ....

Post by **Spike** » Wed Apr 13, 2005 10:49 am

The other day I tackled the job of fabricating the elevator stiffeners for the right elevator. After having fabricated the rudder stiffeners by hand using snips and a scotchbrite wheel I promptly went out an purchased a band saw. The elevator stiffeners were the first thing that I used the new bandsaw on and why I waited so long to purchase one I will never know. Using the band saw and some jigs really makes quick work of the stiffeners. I was able to cut and fabricate the elevator stiffeners assembly line stype in half the time.

The first step was to mark a cut line on one of the stiffeners. Then using one of those handy dandy angle duplicating devices we set it to match the angle of the cut.

Once that angle is set, we then move the duplicator over to the band saw and set it parallel to the blade. We then adjust the saw's fence to match the other side of the duplicator.

Now when you set the part up against the fence, the cut angle will be properly set. The only thing left to do is position the part such that the blade cuts the part where you want it to.

The only potentially hairy part of this if if your fence does not have enough angle of adjustability to cut the part as needed. Typically this would occur if making a cut that is at a very small angle from the saw blade. This is not a big deal though. Usually you can make a jig to fix this. When I ran into this I cut the jig so that it created a 45 degree angle to the blade when the fence was at 90 degrees. By putting the fence at 45 degrees, the jig was now parallel to the blade. I Could then back the fence off until the angle between the jig and the blade was what I needed.

With the bandsaw cutting the metal like butter combined with having the correct angle set into the saw, I could make the parts pretty quick. Simply take a few minutes, set the angle and then run all of the parts through. Reset the angle for the next cut, run the parts through, so forth and so on.

It is a great way to create a bunch of parts quickly and takes away some of the chance of error between repetitions.

-- Spike

dirtmanf800 · Post by **dirtmanf800** » Wed Apr 13, 2005 5:22 pm

who makes the saw your using and what model

bmurrish · Post by **bmurrish** » Wed Apr 13, 2005 7:49 pm

Looks like a Delta that you get from Lowes for around $89. Same one I use that acts like cutting butter with a hot knife.

dirtmanf800 · Post by **dirtmanf800** » Wed Apr 13, 2005 10:26 pm

I noticed the delta emblem in one of the photos, after posting the question

Did you get a different blade for it or just use the one that comes on it

bmurrish · Post by **bmurrish** » Wed Apr 13, 2005 11:31 pm

I went with a 15 TPI blade from Lowes. Cost me under $5

spikescopilot · Post by **spikescopilot** » Thu Apr 14, 2005 8:10 am

Not sure what Spike got, but I know he got a different blade in the last week or so -- then promptly kicked himself for not buying it up front since it made such easy work of the metal. He can probably elaborate when he gets back.

Post by **Spike** » Sun Apr 17, 2005 4:39 pm

Hey Guys,
I am thinking that it the blad is on the order of 16 or 18tpi.

-- John

dirtmanf800 · Post by **dirtmanf800** » Sun Apr 17, 2005 7:03 pm

did the blade come from lowes as well

Looking forward to an overtime check this week

i see a tool trip coming up

Post by **Spike** » Sun Apr 17, 2005 7:18 pm

Yes it did. It was cheap too

did the blade come from lowes as well Looking forward to an overtime check this week i see a tool trip coming up

------------------------------------------------------- www.rivetbangers.com - Now integrating web and mail! www.spikesplace.org/cgi-php/serendipity - Builder's log[/code]
Submitted via email

Guest · Post by **Guest** » Sun Apr 17, 2005 8:14 pm

If you liked the band saw, try a shear!!!