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Cutting 2024 Alclad with a box cutter

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  • Cutting 2024 Alclad with a box cutter

    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
    Bearhawk "XHawk" Patrol, O-360, Trailblazer 80", tubeless 26" Goodyears, Stewart Systems. See XHawk Build Log.

  • #2
    Thanks for taking the time to create and share the video. I have used an Olfa knife with good results.

    Comment


    • gregc
      gregc commented
      Editing a comment
      I like the Olfa knife also. Sometimes it's the perfect solution.

  • #3
    Thanks for sharing this and creating the video. Would not have thought of this. Was it .032” in thickness?

    Comment


    • noema
      noema commented
      Editing a comment
      Patrol boot cowl is .025". I haven't tried any thicker sheets.

  • #4
    olfa.jpg
    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.

    papercutter.jpg

    Also these tools helpful.
    edge1.jpgedge2.jpgsand.jpg





    Stan
    Austin Tx

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