Teardrops n Tiny Travel Trailers

Help somebody: I bought 040 aluminum for my tear, because it was the width I needed and the price was right. Now, I am about to put on the sides and here is the problem. This stuff is very hard to cut. If I glue it onto the side how do you guys trim it off flush? If I cut it to fit first, I still have to leave it a little large to trim down flush. Some have recommended using a router with a speed control. That didn't work for me. When I used it under full speed, I smoked the bit!..I was thinking of using an air nibbler which leaves about 3/16" above the top and then taking a die grinder and try to smooth it out. What do you think. Any suggestions welcome. thanks, Rod

Hey Roddy,

I didn't use a "nibbler" I used air shears. With the Air Shears the bottom blade slides right along the edge of the top and cuts the side virtually even with the top. No need to file or sand very much.

My bad, It was shears, not nibblers I used

Roddy - Air shears as Geron suggested. If you don't have air, there are electric shears that work fine on .040". Suggestion: Lay up the side panel & clamp in place. Scribe the backside by following the outline of your profile. Remove & cut on a clean surface. Shears tend to gouge the aluminum. Cutting on the backside prevents damage to the outside surface.

Fred

:peace:

...use air shears...mark it out and cut...you can use the side as a template/guide for the shears or mark the al and then freehand it...we used our templates as a guide for the shear.....
madjack

I used a hacksaw blade on my jigsaw when cutting my .040. Had to file it a bit, but otherwise no problem.

Joseph

I used a router to cut the aluminum after it was glued to the sides, and a hacksaw blade in a jigsaw to cut it to length. I would do neither again because of the metal cuttings getting under the saw and router scratching the aluminum. I would try the air shears.