Cutting spars to length

[Barry]

Guys, I am ready to rivet my first spar together. Before I do, does anyone have a suggestion on the best way to get a clean cut on the ends of the spars? I need to match cut the web to the shape of the attach plates and I also want a nice clean cut, square on the end too. Thanks!

[DesertBearhawk]

I used the same patterns I used to make the attach plates and the router table. Takes about 10 seconds and its a perfect match....

[Barry]

Thanks Dave, sounds like a plan!

[DesertBearhawk]

You will need to take a hacksaw or whatever and cut the vertical cut on the flange and then just clean it up with the router table….

[Barry]

Thanks again Dave!

[Phil]

For the square end I'm planning to use a non-ferrous metals blade in my miter saw. For the attach bracket ends I plan to clamp the brackets into place and use a trim bit in a router to match them up.

[N3UW]

I marked it with a sharpie using the spar attach plate. I then used a dremel tool with a cutoff wheel to get within 1/16" of the line. I then put the spar attach plate back on and secured it. I the used a sanding wheel on the dremel to sand to th spar attach plate, Then cleaned it up with scotchbrite wheel.