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HomeAircraftHelicopterHelicopter Main Discussion › Custom Frame
03-03-2018 04:39 AM  8 months agoPost 21


Middletown Ohio

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Ok thank you for the information

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03-07-2018 07:51 PM  8 months agoPost 22

rrElite Veteran

W. Bridgewater, MA USA

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I have made copies of frames before. I used aluminum but you could use G10 too (and maybe cf if you can figure a way to rough cut it). First using the original frame as a template drill out all the screw holes. Trace the frame and rough cut it out with a bandsaw. Use a jig saw for the inside holes. Bolt the original frame to the copy using screw holes but put a nut in between them to hold them separated. Then i used a 3mm high speed carbide burr in my drill press that i had put a smooth wooden base on. Lay the 2 frames on the wood base with the original frame up. Plunge the burr into the wood so that the cutting surface lines up with the home made frame, but the smooth surface lines up with the original frame. Lock it there. Crank the drill press up as fast as it will go and slowly start moving the 2 frames together sitting on the wood base against the cutter. Go slow and hold tight!! If you try to remove too fast it can rip the whole thing out of your hands. Once the smooth part of the cutter hits the original frame it will not cut anymore and it will make a perfect copy

03-07-2018 11:17 PM  8 months agoPost 23

rrKey Veteran

Morgan Hill, CA. USA

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What he said.
But, if you look for a Flush Trim Router Bit with a carbide blade, it does the same thing, only you can use a high speed router instead of a drill press

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03-08-2018 01:21 AM  8 months agoPost 24


Mexico city

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Thanks GMPheli for your advice. The idea of using a nut to separate the frame and then use the smooth surface of the cutter sounds great to me.
How about a bench top router table, has anyone tried it to cut frames?
Since a router is very high speed I think it can be useful for this purpose specialy when cutting carbon fiber.

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HomeAircraftHelicopterHelicopter Main Discussion › Custom Frame
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