SonexBuilders.net

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

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.

I used my table saw with 80 tooth carbide blade . Cut very slowly .

Bandsaw here. Worked fine.

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

Not much dust gets thrown up when cutting lead.

Old school hack saw. Very easy.
Peter

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

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.

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