Posted: 2/11/2010 20:54:29
What's the best way to make plywood gussets? I've tried a hole saw and a circle cutter with varying results. Any suggestions? I'm a new builder (VP2) and learning as I go along. . . . .
Posted: 2/11/2010 21:52:02
Hi Martin, welcome to the forum and to homebulding!
I think you're looking for tips on how to cut the numerous holes that are in the plywood wing ribs on the VP2 (?)
If so, a router might work for you. I needed to do a similar job on the wing ribs of my Sopwth Pup replica and this video got me started with the basic principle, although I did eventually end up using a table router - -
Posted: 2/11/2010 22:24:22
No, I'm fine with the holes in the ribs, used a hole saw with no problems. I've almost completed the rudder and have started on the stabilator. My problem is finding a quick and easy way of making the little semi circular strengthening gussets out of 1/16th ply. I can do them with a hole saw but they need cleaning up after and it's quite time consuming doing a bunch of them. I'm looking for a way of punching them out on masse so to speak!
BTW, I did use the router method for cutting out my stabilator ribs, quick and effective.
Posted: 2/12/2010 12:05:14
Do they need to be semi-circular? Most times you can get away with triangular (or rectangular or whatever). I made mine using a very fine tooth blade on my table saw. I stacked a number of sheets of plywood up and cut out the gussets, making a whole bunch at one time. Semi-circular may look a little fancier, but there's no strength advantage over straight-sided gussets.
Lasciate ogne speranza, voi ch'intrate
Posted: 2/12/2010 16:51:22
I'd stack them up, clamp the stack and then cut them out using either a router or a table saw. With a table saw I'd make the gussets triangular or rectangular with clipped (Dogeared) corners. It isn't that much heavier and you can get them cut in a jiffy. Once their cut, put them in a plastic bag of say 25 or a hundred to keep them from absorbing moisture or oil. Then take as many as you'll need to make the ribs/trusses you're going to do in that session.
Posted: 2/12/2010 19:21:04
Thanks All. I never thought of making them triangular! I was just dutifully following the plans without thinking for myself. . . . . .
Posted: 2/14/2010 21:41:23
Modified: 2/14/2010 21:58:17
You need a collection of vintage EAA magazines to get you through, my friend! Here's a punch designed exclusively for this purpose. You can make it yourself. From the March 1960 Sport Aviation magazine.
If this isn't exactly what you're looking for, then I don't know what is.
Best of luck on your project!
Posted: 2/14/2010 22:01:51
Outstanding use of the online archive Wayne! A tip that will be 50 years old next month, still valuable today.
Posted: 2/15/2010 22:35:19
Thank you so much, that's exactly what I need. What a marvellous resource we have available in "Sport Aviation", I obviously need to spend some time reading. . . .
Posted: 2/21/2010 08:54:19
I had to make a bunch of 1/16" triangular gussets for a recent project and used a good sharp paper cutter. Made a nice clean edge and was fast. A sheet metal shear - if you have access to one works good too. Greg