Lead counterbalance weight for Ailerons

[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

[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.

[Mike53]

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

[Bryan Cotton]

Bandsaw here. Worked fine.

[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

[Area 51%]

Not much dust gets thrown up when cutting lead.

[pfhoeycfi]

Old school hack saw. Very easy.
Peter

[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

[DCASonex]

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.

[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