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  1. #1

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    how to cut aluminum??

    any advice?
    i am trying to lighten this backplate. keeping in mind, that when i am done, i will balance it.
    it is 5" spinner
    this is what i got so far and
    i have decreased it by 1 and 1/8 ounce.
    i have used a router aluminum bit X 2 (35 dollars)
    and a 1 inch drill (30 dollars) did not work.
    i could have bought the Tru turn spinner by now, but i am hard headed, so i am making a project out of it.
    trying to figure out what else i can use to finish this off??
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  2. #2
    sensei's Avatar
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    RE: how to cut aluminum??

    Forget the router, it turns too fast use a drill press and get a UNI-Bit or piloted counter bores to get the job done at slower speeds. Just about any aircraft sheet metal mechanic can show you the way and will have these tools in his tool box if you know any.

    Bob
    Fly It Like You Stole It!!!

  3. #3
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    RE: how to cut aluminum??

    Was there a pic to go with your post? Are you just trying to drill holes in it to lighten it up, or are you trying to mill down the thickness?
    Jerry
    AMA -922698 Nomal people scare me, but not as much as I scare them...

  4. #4
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    RE: how to cut aluminum??

    OK I just saw the pics on another sight; so from where you are at to this point you are going to need a compressor, die grinder with a 1/4" collet, and 1/4" shanked fluted metal cutting bits to finish the job. You can get everything you need at very reasonable prices from Harbor Freight, just take your time and place it on the balancer many times as you go.

    Bob
    Fly It Like You Stole It!!!

  5. #5

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    RE: how to cut aluminum??

    i am unable to post pictures on this site,  anyone have any advice.
    AMA # 982277
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  6. #6

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    RE: how to cut aluminum??

    At this rate you are doing a better job lightening your wallet than the back plate. You might want to consider buying a new lighten version! But if you are having fun than go for it.
    Tony Hallo

  7. #7

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    RE: how to cut aluminum??

    wow, i got the backplate down to 2 1/4 ounces.

    it originally weighed 5 1/8 ounces.
    AMA # 982277
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  8. #8

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    RE: how to cut aluminum??

    ,
    Jim
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  9. #9

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    RE: how to cut aluminum??

    When you lighten the back plate you will need a front support for the spinner.
    Darryl
    Usher Tool

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  10. #10
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    RE: how to cut aluminum??

    I read that you decided not to use your modified backplate, thats really OK because you still learned from this experience and I am sure you will apply it later down the road.

    Bob
    Fly It Like You Stole It!!!

  11. #11

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    RE: how to cut aluminum??

    i have decided i will not be using this.  i will buy a new one. thank you all for comments.
    AMA # 982277
    3DHS Extra 330 SC 119" DA 170
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  12. #12

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    RE: how to cut aluminum??

    that's right bob,
    i learned so much
    it was fun, and it was an exercise in using high speed routers.
    AMA # 982277
    3DHS Extra 330 SC 119" DA 170
    Bill Hempel Yak 40% DA 170
    Extreme Flight Extra 300 91" DA 60 MTW RE2
    Great Planes Matt Chapman Eagle Cap DA 120
    Extreme FLight Extra 300 78" DA35 (Soon)
    Hangar 9 Extra 260 DA50
    GP Revolver 70 Saito FA1.25

  13. #13

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    RE: how to cut aluminum??

    And sweeping up alum. shavings?

  14. #14

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    RE: how to cut aluminum??

    oh yeah, and one impaled me under my eye, even though  i was wearing eye protection.  looks like i got some swelling there right now.  i press deep and there is no pain, so i do not believe there is any metal left in there.
    AMA # 982277
    3DHS Extra 330 SC 119" DA 170
    Bill Hempel Yak 40% DA 170
    Extreme Flight Extra 300 91" DA 60 MTW RE2
    Great Planes Matt Chapman Eagle Cap DA 120
    Extreme FLight Extra 300 78" DA35 (Soon)
    Hangar 9 Extra 260 DA50
    GP Revolver 70 Saito FA1.25

  15. #15

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    RE: how to cut aluminum??

    5 inch spinner, must be a big plane, shaving 2 ounces on the backplate wont to anything for CG changes, if that is why you tried to lighten it.
    Take care of the eye, metal fragments can be nasty.

  16. #16

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    RE: how to cut aluminum??

    Hi Nitro, you would not believe it, but the balance of plane was within ounces. but it turned out plane was tail heavy, so i re-ordered the backplate and spinner.

    ORIGINAL: nitro wing

    5 inch spinner, must be a big plane, shaving 2 ounces on the backplate wont to anything for CG changes, if that is why you tried to lighten it.
    Take care of the eye, metal fragments can be nasty.
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    AMA # 982277
    3DHS Extra 330 SC 119" DA 170
    Bill Hempel Yak 40% DA 170
    Extreme Flight Extra 300 91" DA 60 MTW RE2
    Great Planes Matt Chapman Eagle Cap DA 120
    Extreme FLight Extra 300 78" DA35 (Soon)
    Hangar 9 Extra 260 DA50
    GP Revolver 70 Saito FA1.25

  17. #17

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    RE: how to cut aluminum??

    i put in 4 servos for the elevators, 2 on each stab half.  each servo has 500 ou/torque/in
    each servo weighs 2 ounces.
    the two extra servos is 4 ounces
    but at the nose, it is equivalent to 8 ounces needed to counterbalance it.  i did not remove the two extra servos, instead, i undid all my canopy work, and removed the pilot and the instrument panel, and then i perforated the electronics tray.  by doing so, i removed over 1 pound off the plane.
    AMA # 982277
    3DHS Extra 330 SC 119" DA 170
    Bill Hempel Yak 40% DA 170
    Extreme Flight Extra 300 91" DA 60 MTW RE2
    Great Planes Matt Chapman Eagle Cap DA 120
    Extreme FLight Extra 300 78" DA35 (Soon)
    Hangar 9 Extra 260 DA50
    GP Revolver 70 Saito FA1.25


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