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Wondering if anyone has any helpful tips on cutting the lead blocks for the aileron counterbalance. I'm thinking of trying the bandsaw with a wood cutting blade, with plenty of wax. I read that it can bind up and get stuck in the lead, but I don't know that I have any better options/plan.

I think the band saw was what I used. During my build I only had a metal cutting blade in my saw.

Hi guy,all,
I used my small Ryobyi table saw with a metal cutting blade. Drew a black felt tip line corner to corner. Safety glasses and gloves. Cut like butter. Lots of chips. The pieces came out perfect , cut line smooth, fit the alum. Support bars perfect. Blade width about 1/8 in. A band saw would work , but maybe a metal cutting blade?

WaiexN143NM
Michael

I used a Harbor Freight three wheel band saw with a 14 tpi blade and lots of candle wax. It cut easily and took a small kerf. The wood band saw has been used by many builders with no problems. Use lots of wax and go slow, you'll be fine.

A band saw blade that is made for metal is not going to be your friend. Tried to use the one I was cutting aluminum with. It will plug up chop-chop. I used a wood blade I had on hand (don't remember the tooth count, but it was coarse). Didn't use any wax (didn't have any), so I did have to stop and clear the teeth often. Good results in the end though.

Report: My bandsaw with wood-cutting blade worked perfectly and easily. Must remember to avoid analysis paralysis.

Of note to future lead cutters/drillers: the was is absolutely essential. Taking the time to re-wax the blade/bit every few seconds makes the job so much easier and cleaner.

Don't pilot drill lead with small bits. A #40 will give you grief!

If cutting is too difficult, make a form and melt it into what you need it to be. Then go from there. Maybe.

Hi all,
Good to hear a 'wood' bandsaw blade works well for cutting the lead. One question for the guys who did this and used wax, are you rubbing wax on the sides and or teeth of the blade? Or are you using a candle (lit) and using liquid wax at the cut line? I'm sure a helper during this process would make it much easier .

WaiexN143NM
Michael

I have always just rubbed the candle on each side of the blade. You are trying to keep the sides of the blade from rubbing on the kerf of the cut to reduce friction, not trying to lubricate the teeth doing the actual cutting. A slow feed is also good to keep heat down and allow the teeth to clear the chips from the cut.

Keith
#554