Quote:
Originally Posted by John Buchtenkirch
Ed, the problem is the thin sheet is floppy and bends while you’re trying to cut it, while stiffer wood or even thicker steel are relatively much easier materials to make an accurate cut with. If I had to make maybe 50 pieces or more I’d cut a pair perfectly to check the fit-up and then flatten one out to use as a pattern to scribe mark the end cuts and trim them by hand with snips. I look at that accurate cut as being one of the trickiest parts of the job.
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When I need to make many pieces like this I make a clamping mold, two pieces that match the inside and outside of the profile makes it easy to clamp in my horisontal bandsaw, then I got perfect cuts everytime.