Chassis-bashing revisited
 

Hi,

Whatever metal-working skills I acquired during my training as
a radar fitter in the Royal Air Force so many year ago have
evaporated it would seem (RAF Locking 1958). Just now I tried to
cut some short strips from a 3mm aluminium sheet using a hacksaw
and made the worst possible mess of it.

No matter how I tried, I couldn't stop the cut veering to the
right. In the end I just cut out the pieces larger than required
and filed them to shape. The end result was OK but what a waste
of material.

So, what is the technique for hacksawing a straight-ish line
by hand. I guess that as my cuts always went the same way it was
something to do with how I was standing and holding the hacksaw.
Any tips would be gratefully received.

All those years ago I passed the necessary trade tests so I
must have had it down pat then.


73 de Joe, G3LLV

No matter how I tried, I couldn't stop the cut veering to the
right. In the end I just cut out the pieces larger than required
and filed them to shape. The end result was OK but what a waste
of material.

So, what is the technique for hacksawing a straight-ish line
by hand. I guess that as my cuts always went the same way it was
something to do with how I was standing and holding the hacksaw.
Any tips would be gratefully received.

Joe,

Of course, what would be nice for this job would be a high power laser, but I
don't have one either. Lacking such sophisticated tools, we just do the best we
can with what we have. Use a hacksaw blade with a fine pitch, make sure the
blade is tight, and cut at a small angle so more of the blade is guided by the
part you've already cut. (30 degrees good, 90 degrees bad.)

Some kinds of large tin snips are easier to control, but tend to curl the
material more than a saw blade. A nibbling tool is OK for small pieces, but
will quickly wear out your hand.

I've been hacking, punching, snipping and drilling holes in chassis since 1953.

Hope some of that helps.

Doug Moore KB9TMY (Formerly K6HWY)

No matter how I tried, I couldn't stop the cut veering to the
right. In the end I just cut out the pieces larger than required
and filed them to shape. The end result was OK but what a waste
of material.

So, what is the technique for hacksawing a straight-ish line
by hand. I guess that as my cuts always went the same way it was
something to do with how I was standing and holding the hacksaw.
Any tips would be gratefully received.

Joe,

Of course, what would be nice for this job would be a high power laser, but I
don't have one either. Lacking such sophisticated tools, we just do the best we
can with what we have. Use a hacksaw blade with a fine pitch, make sure the
blade is tight, and cut at a small angle so more of the blade is guided by the
part you've already cut. (30 degrees good, 90 degrees bad.)

Some kinds of large tin snips are easier to control, but tend to curl the
material more than a saw blade. A nibbling tool is OK for small pieces, but
will quickly wear out your hand.

I've been hacking, punching, snipping and drilling holes in chassis since 1953.

Hope some of that helps.

Doug Moore KB9TMY (Formerly K6HWY)

"Joe McElvenney" wrote in message
...
Hi,

Whatever metal-working skills I acquired during my training as
a radar fitter in the Royal Air Force so many year ago have
evaporated it would seem (RAF Locking 1958). Just now I tried to
cut some short strips from a 3mm aluminium sheet using a hacksaw
and made the worst possible mess of it.

No matter how I tried, I couldn't stop the cut veering to the
right. In the end I just cut out the pieces larger than required
and filed them to shape. The end result was OK but what a waste
of material.

So, what is the technique for hacksawing a straight-ish line
by hand. I guess that as my cuts always went the same way it was
something to do with how I was standing and holding the hacksaw.
Any tips would be gratefully received.

Instead of sawing it, try scoring it on both sides with a Stanley knife,
then bend it backwards and forwards. It will snap along the scoring, quite
quickly.

Leon
--
Leon Heller, G1HSM

http://www.geocities.com/leon_heller

"Joe McElvenney" wrote in message
...
Hi,

Whatever metal-working skills I acquired during my training as
a radar fitter in the Royal Air Force so many year ago have
evaporated it would seem (RAF Locking 1958). Just now I tried to
cut some short strips from a 3mm aluminium sheet using a hacksaw
and made the worst possible mess of it.

No matter how I tried, I couldn't stop the cut veering to the
right. In the end I just cut out the pieces larger than required
and filed them to shape. The end result was OK but what a waste
of material.

So, what is the technique for hacksawing a straight-ish line
by hand. I guess that as my cuts always went the same way it was
something to do with how I was standing and holding the hacksaw.
Any tips would be gratefully received.

Instead of sawing it, try scoring it on both sides with a Stanley knife,
then bend it backwards and forwards. It will snap along the scoring, quite
quickly.

Leon
--
Leon Heller, G1HSM

http://www.geocities.com/leon_heller

3mm is about .120" ...
reasonably thick stuff..
Al tends to gall so use a suitable blade and make sure tooth spacing is
significantly under 3mm..
Scribe a good line and clamp between two boards or plates..
Also try using oil or water as you cut with the saw at an angle..
Failing that find a place with a shear!
I was in the RCAF in 1959 and as best I can recall everything fit.
Mostly stuff from south of the border.
73
hank wd5jfr
"Joe McElvenney" wrote in message
...
Hi,

Whatever metal-working skills I acquired during my training as
a radar fitter in the Royal Air Force so many year ago have
evaporated it would seem (RAF Locking 1958). Just now I tried to
cut some short strips from a 3mm aluminium sheet using a hacksaw
and made the worst possible mess of it.

No matter how I tried, I couldn't stop the cut veering to the
right. In the end I just cut out the pieces larger than required
and filed them to shape. The end result was OK but what a waste
of material.

So, what is the technique for hacksawing a straight-ish line
by hand. I guess that as my cuts always went the same way it was
something to do with how I was standing and holding the hacksaw.
Any tips would be gratefully received.

All those years ago I passed the necessary trade tests so I
must have had it down pat then.


73 de Joe, G3LLV

3mm is about .120" ...
reasonably thick stuff..
Al tends to gall so use a suitable blade and make sure tooth spacing is
significantly under 3mm..
Scribe a good line and clamp between two boards or plates..
Also try using oil or water as you cut with the saw at an angle..
Failing that find a place with a shear!
I was in the RCAF in 1959 and as best I can recall everything fit.
Mostly stuff from south of the border.
73
hank wd5jfr
"Joe McElvenney" wrote in message
...
Hi,

Whatever metal-working skills I acquired during my training as
a radar fitter in the Royal Air Force so many year ago have
evaporated it would seem (RAF Locking 1958). Just now I tried to
cut some short strips from a 3mm aluminium sheet using a hacksaw
and made the worst possible mess of it.

No matter how I tried, I couldn't stop the cut veering to the
right. In the end I just cut out the pieces larger than required
and filed them to shape. The end result was OK but what a waste
of material.

So, what is the technique for hacksawing a straight-ish line
by hand. I guess that as my cuts always went the same way it was
something to do with how I was standing and holding the hacksaw.
Any tips would be gratefully received.

All those years ago I passed the necessary trade tests so I
must have had it down pat then.


73 de Joe, G3LLV

On Thu, 04 Sep 2003 20:07:49 +0100, Joe McElvenney hath writ:
Hi,

Whatever metal-working skills I acquired during my training as
a radar fitter in the Royal Air Force so many year ago have
evaporated it would seem (RAF Locking 1958). Just now I tried to
cut some short strips from a 3mm aluminium sheet using a hacksaw
and made the worst possible mess of it.

No matter how I tried, I couldn't stop the cut veering to the
right. In the end I just cut out the pieces larger than required
and filed them to shape. The end result was OK but what a waste
of material.

So, what is the technique for hacksawing a straight-ish line
by hand. I guess that as my cuts always went the same way it was
something to do with how I was standing and holding the hacksaw.
Any tips would be gratefully received.

All those years ago I passed the necessary trade tests so I
must have had it down pat then.

73 de Joe, G3LLV

I usually clamp a thick, "sacrificial" straight-edge along the line
to be cut. Use another "straight edge" on the back side -- but a wee
bit back from the scribed line. Clamp at as many points as practical.
Cut on the "outside" edge -- of course. Go slow , and , as another
poster mentioned: Cut at a 45-30 degree angle. "90 degrees == bad."

HTH es 73
Jonesy
--
| Marvin L Jones | jonz | W3DHJ | OS/2
| Gunnison, Colorado | @ | Jonesy | linux __
| 7,703' -- 2,345m | config.com | DM68mn SK

On Thu, 04 Sep 2003 20:07:49 +0100, Joe McElvenney hath writ:
Hi,

Whatever metal-working skills I acquired during my training as
a radar fitter in the Royal Air Force so many year ago have
evaporated it would seem (RAF Locking 1958). Just now I tried to
cut some short strips from a 3mm aluminium sheet using a hacksaw
and made the worst possible mess of it.

No matter how I tried, I couldn't stop the cut veering to the
right. In the end I just cut out the pieces larger than required
and filed them to shape. The end result was OK but what a waste
of material.

So, what is the technique for hacksawing a straight-ish line
by hand. I guess that as my cuts always went the same way it was
something to do with how I was standing and holding the hacksaw.
Any tips would be gratefully received.

All those years ago I passed the necessary trade tests so I
must have had it down pat then.

73 de Joe, G3LLV

I usually clamp a thick, "sacrificial" straight-edge along the line
to be cut. Use another "straight edge" on the back side -- but a wee
bit back from the scribed line. Clamp at as many points as practical.
Cut on the "outside" edge -- of course. Go slow , and , as another
poster mentioned: Cut at a 45-30 degree angle. "90 degrees == bad."

HTH es 73
Jonesy
--
| Marvin L Jones | jonz | W3DHJ | OS/2
| Gunnison, Colorado | @ | Jonesy | linux __
| 7,703' -- 2,345m | config.com | DM68mn SK

A "nibler", a one-hand operated, very short-bladed shears is useful. You can
also guide this tool round curves in sheet metal similar to a pair of
sissors if needed.

--
=======================
Regards from Reg, G4FGQ
For Free Radio Design Software
go to http://www.g4fgq.com
=======================
"Joe McElvenney" wrote in message
...
Hi,

Whatever metal-working skills I acquired during my training as
a radar fitter in the Royal Air Force so many year ago have
evaporated it would seem (RAF Locking 1958). Just now I tried to
cut some short strips from a 3mm aluminium sheet using a hacksaw
and made the worst possible mess of it.

No matter how I tried, I couldn't stop the cut veering to the
right. In the end I just cut out the pieces larger than required
and filed them to shape. The end result was OK but what a waste
of material.

So, what is the technique for hacksawing a straight-ish line
by hand. I guess that as my cuts always went the same way it was
something to do with how I was standing and holding the hacksaw.
Any tips would be gratefully received.

All those years ago I passed the necessary trade tests so I
must have had it down pat then.


73 de Joe, G3LLV