Quick Tips – Sheet Metal

While watching some YouTube videos, I noticed some sheet metal tips in the comments that I thought were worth keeping. Here they are:

  1. The only time you use a Vixen file is for heavy shaping.
  2. There is no need to debur your pats before you drill, you will only have to debur it again.
  3. There is no need to ream a hole for a rivet, only when you use a Hi-Lok (close tolerance hole).
  4. When you do use a reamer, once you have taken the hole up to proper size, stop the drill motor and gently pull the reamer out or you will make your hole to big and it will be out of tolerance (close tolerance holes).
  5. When you do get to the point of deburring your parts use a scotch bright disc and a side grinder (much faster).
  6. When you round your corners the radius should be between 1/8 & 1/4 (or .125 & .250), it’s a stress thing when the metal parts come together. the sharper the point, the more the possibility for stress at the point. You can also make it a 45º chamfer, but I prefer a radius.

Another great tip from Guil was that for machine countersinking, cut to hold a rivet flush, then 7 clicks (.007″) more to accommodate the dimpled piece that will eventually sit inside it.

About Michael Carter

Programmer, Pilot/Builder and Amateur Radio enthusiast living in the Bay Area of California.
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