I used a table saw and later a radial arm saw with abrasive cutting wheels
from the local lumberyard/hardware. Works just like cutting wood, but
noisier and smellier. Be careful cover the wood table (if the saw table
isn't metal) with a sheet of metal or the sparks will cause charring. I've
cut up to .120 4130 this way and it works fine.

I wouldn't use this method for huge projects, since the grit is messy and
hard on the saw if you don't clean it well, but for the occasional part, it
worked well, cutting straight lines and fairly quickly.

"Ernest Christley" wrote in message
. com...
I've got some .035 4130 that I have to cut elevon ribs from. 2 inch on
one end, 3/8ths on the other and about 16" long (each one is a different
length). The small end fits against a run of tube, the thick end against
the elevon spar. Both ends have to be shaped appropriately. The sides
of the long runs need to be perfectly straight. I've seen a lot of
options on how to cut aluminum, but the info on steel seems to be more
limited. Here's where I'm at so far.

A shear big and strong enough to handle the job is currently out of my
budget. (though, I keep hearing that the economy is coming back around)

Harbor Freight has a $35 cutting tool that can handle the job according
to the advertised specs. It sorta, kinda looks like an angle grinder,
except that it has a short arm and a reciprocating tooth out one side.
I figure I can drill a 3/8" hole, clamp a 2x4 to each side of the sheet
as guides, and just make a run with the cutter. Anyone have experience
with these things? Do they leave a clean edge?

Another option is to pay a machine shop. If I can find a good shop, I'm
sure to get quality work, but I can't say that I did it and I won't have
a tool afterward. I'm saving that as a last resort.

Are there any better options?

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