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Gary's RV8 Construction Log
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Date:  10-11-2010
Number of Hours:  3.00
Manual Reference:  
Brief Description:  F/Tanks: T405 Attachment Brackets

I started by drilling out the holes for the relevent radii on both parts - I found a 12mm drill (i.e. 6mm radius) worked well for me. I then started cutting roughly on the outside of the lines using a hacksaw - after ione cut, I thought "Nah! - Gotta be a better way!"

Not having a bandsaw, I took a spare peice of alu angle and fired up the Mitre Saw. I very very slowly cut through the angle - no sweat what-so-ever! I then proceeded to rough cut the angles on the mitre saw - taking it very slowly and being extra careful - the saw didn't hiccup or grab the material (my biggest fear) once.

I then started working it closer to the desired shape on the belt sander - it took a while but it did a way better job than the grinder (which was useless by the way). It's actually amazing how fast a belt sander eats its way through aluminium.

Once I had my desired shaped, I smoothed it all out to silky lustre we all like on the scotchbrite wheel. I was actually dreading these brackets but they really turned out to be a non-entity!
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Holes drilled to provide a 6mm internal radius

Holes drilled to provide a 6mm internal radius

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Rough cut to shape on the mitre saw

Rough cut to shape on the mitre saw

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Perfect fit and all nice and silky to boot!

Perfect fit and all nice and silky to boot!

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