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After realizing that I cut the original wing spar form from the wrong thickness metal, I was able to take advantage of a warm Saturday to cut a new form with the correct stock. I was able to use the original stock as a guide as I cut the form with an Olfa knife. It wasn't easy but I got a straight and clean cut. The form in the photos look ragged but I left the protective coating on.
Comment
It might work David, I don't have one so I haven't tried that.
David,
I cut my .063" and .125" material with a skill saw to rough size then filed from there. I am not necessarially recommending this method but it's what I do. Be carfull if you go this route and WEAR SAFTEY GLASSES this method throws a lot of chips (and makes almost as much mess as routing).
Jesse Hartman and I are planning on going to the sheet metal shop and having them shear a 4x12 sheet of 0.040 to the right width for our plans build wing spars. 0.040 is hard to cut.
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