I have had some great ideas from you guys on methods of making the sweep fillets for my I struts. This has been a really good help. Thanks.
Photos below to show my progress.
I used walnut shells to load the aluminum tube for bending, why? 'cause I had them and no silica dust.
Then I cut a circular form to pull the tube around.
Having roughly marked the appropriate lines I used a fine blade on my metal cutting band saw and then final shaped the profile on my stationary 12" disc sander.
I used 3M Panel Bonding Adhesive to attach the fillets to the I strut tube work.
Because there is only partial contact of aluminum fillet to I strut steel tube. I will leave the 3M stuff to cure and then sort of calk the edges again with the Bonding Adhesive.
Photos below to show my progress.
I used walnut shells to load the aluminum tube for bending, why? 'cause I had them and no silica dust.
Then I cut a circular form to pull the tube around.
Having roughly marked the appropriate lines I used a fine blade on my metal cutting band saw and then final shaped the profile on my stationary 12" disc sander.
I used 3M Panel Bonding Adhesive to attach the fillets to the I strut tube work.
Because there is only partial contact of aluminum fillet to I strut steel tube. I will leave the 3M stuff to cure and then sort of calk the edges again with the Bonding Adhesive.
![DSCN1819 (800x600).jpg DSCN1819 (800x600).jpg](https://cdn.imagearchive.com/biplaneforum/data/attach/17/17152-DSCN1819-800x600-.jpg)
![DSCN1820 (800x600).jpg DSCN1820 (800x600).jpg](https://cdn.imagearchive.com/biplaneforum/data/attach/17/17153-DSCN1820-800x600-.jpg)
![DSCN1827 (800x600).jpg DSCN1827 (800x600).jpg](https://cdn.imagearchive.com/biplaneforum/data/attach/17/17154-DSCN1827-800x600-.jpg)
![DSCN1828 (800x600).jpg DSCN1828 (800x600).jpg](https://cdn.imagearchive.com/biplaneforum/data/attach/17/17155-DSCN1828-800x600-.jpg)
![DSCN1829 (800x600).jpg DSCN1829 (800x600).jpg](https://cdn.imagearchive.com/biplaneforum/data/attach/17/17156-DSCN1829-800x600-.jpg)
![DSCN1830 (800x600).jpg DSCN1830 (800x600).jpg](https://cdn.imagearchive.com/biplaneforum/data/attach/17/17157-DSCN1830-800x600-.jpg)
![DSCN1831 (800x600).jpg DSCN1831 (800x600).jpg](https://cdn.imagearchive.com/biplaneforum/data/attach/17/17158-DSCN1831-800x600-.jpg)
![DSCN1832 (800x600).jpg DSCN1832 (800x600).jpg](https://cdn.imagearchive.com/biplaneforum/data/attach/17/17159-DSCN1832-800x600-.jpg)
![DSCN1833 (800x600).jpg DSCN1833 (800x600).jpg](https://cdn.imagearchive.com/biplaneforum/data/attach/17/17160-DSCN1833-800x600-.jpg)
![DSCN1835 (800x600).jpg DSCN1835 (800x600).jpg](https://cdn.imagearchive.com/biplaneforum/data/attach/17/17161-DSCN1835-800x600-.jpg)
![DSCN1844 (800x600).jpg DSCN1844 (800x600).jpg](https://cdn.imagearchive.com/biplaneforum/data/attach/17/17162-DSCN1844-800x600-.jpg)
![DSCN1839 (800x600).jpg DSCN1839 (800x600).jpg](https://cdn.imagearchive.com/biplaneforum/data/attach/17/17163-DSCN1839-800x600-.jpg)