[NIC 77]

Too cool.

So you're the company that makes the kits?

I haven't flown in years. I'd be lying if I said I didn't miss it.

What size sheets does the aluminum come in? The machine should cut aluminum sheet fine, but at those thicknesses (0.025" to 0.04") I have to wonder if a laser might be a better solution.

Also work holding comes into play here. I can't imagine that you want to put double sided tape on every sheet you cut.

[Bearhawk LSA]

Too cool.

So you're the company that makes the kits?

I haven't flown in years. I'd be lying if I said I didn't miss it.

What size sheets does the aluminum come in? The machine should cut aluminum sheet fine, but at those thicknesses (0.025" to 0.04") I have to wonder if a laser might be a better solution.

Also work holding comes into play here. I can't imagine that you want to put double sided tape on every sheet you cut.

Hello Nic,

Yes I am making the kits, but not for the Bearhawk LSA. I registered long ago when I was about to build one. Wife likes flying enough that the tandem layout of the Bearhawk LSA is a no go. Plus have a infant now so need a 3 place airplane. My website for the plans (kits eventually) is here. Cloudbase Aviation Aircraft Designs – A division of Cloudbase Engineering LLC
Also have a link to some aviation specific Gopro mounts and if you go to that site there are some cool backcountry bush flying videos.

Your correct in that the laser or water jet would be more cost effective and if I get to volume will go that route. I need my own CNC router to develop the kit and test fit as I go. Once parts are finalized, I can then move to have them done on a laser. So for me its more of an R&D machine with maybe light production. Also may add a rotary to the long axis to cut the 4130 tubing with the unique fishmouth for welding. I did the fuselage in Solidworks so have all the files already for each tube. I can get the sheets in 4 x 8, 5 x 10 and in 12' lengths, but will likely use 4 x 8 more often but with the dust shoe on a 4' 8 machine I heard its tough to use the entire sheet so figured 5 x 10 and the extra cost is negligible. Also may need to cut a long part or drill a series of holes in a 10' long spar piece. I also plan to get an ATC spindle since I need to drill various size rivet holes as well.

As for workholding, I plan to either cut and leave tabs not cut that I can snip with a hand shear or, I may have the router run all the drill holes and I can either add a screw here and there, or use a low profile cleco and make sure the dust shoe if used does not hit the clecos. Others just use longer endmills to clear the clecos. I also have a Tormach PCNC1100 series 3 and a 600 x 900 100W Laser cutter. I mostly use the laser to etch serial numbers in anodized parts for my camera mounts and such. Also use it to cut cork, rubber, neoprene, Plexiglass and thin Plywood. I am trying to set myself up with all the machines I need to work on the kits. All in an airplane hangar in Los Angeles area.