Cutting 2024 Alclad with a box cutter

[noema]

I haven't read this anywhere before and discovered this more or less by accident. Scribing and breaking thin Alclad works surprisingly well. When I did some butt joints on my boot cowl I forgot to account for material loss from using a cutter disc. I then tried splitting the sheet metal with a box cutter on a scrap piece. I routinely get results similar to a large table shear (which I don't have).

Also really illustrates the importance of sanding out material imperfections to avoid stress risers.

https://youtu.be/tKNNhMZFQd8

 

[Dpearson]

Thanks for taking the time to create and share the video. I have used an Olfa knife with good results.

 

[Brett795]

Thanks for sharing this and creating the video. Would not have thought of this. Was it .032” in thickness?

 

[gregc]

I like the Olfa knife also. Sometimes it's the perfect solution.

 

[sjt]

I also liked the Olfa knife. I found that I could make fewer cuts by using a brake to snap it.

I also found paper cutters to be handy.



Also these tools helpful.

 

[noema]

Patrol boot cowl is .025". I haven't tried any thicker sheets.