>I butchered them. How do the Experts cut ailerons on glass skins over foam
>and make them perfect, i.e. no wiggles and no mismatches, I need to know.
I use the follow method. It has worked to avoid the "wiggly line" problem
of the blade following weave irregularities:
I actually "scribe" the hinge line over and over with the point of the knife
(NOT "cutting" it with the sharp edge like you might normally do). This way
the knife won't tend to "steer" and wander. You can use the knife edge to
finish the last little bit of the cut once you've scored the skins deeply.
DON'T knife cut through the foam.
After ACCURATELY making cuts on the top and bottom, I take a razor saw
(i.e.; Zona saw) with the back-spine stiffener removed to sever the aileron
or flap foam core from the main wing panel. I also use the Zona saw to cut
the ends of the surfaces, too. The thin blade cuts the foam without balling
it up, and is guided accurately by the cuts in the upper and lower skins.
I have also used a needle point carbide layout scribe instead of the point
of a knife.
Dan deVries
DEVRIES DESIGN, Inc.
Product Design --+-- Patent/Litigation Graphics
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[EMAIL PROTECTED]
Dan deVries
290 - 68th St. SW
Grand Rapids, MI 49548
Office: 616-281-2271
Fax: 616-281-2294
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