Constructed a fence using a 4' ruler and raised the work surface so that the metal cut-off blade would enter at better angle like a chop saw would. A chop saw might have been nice but the radial saw worked out fine.(saved some expense for other toys).

Stop block clamped to fence for proper length to make cuts.

Another of fence and stop block readied to cut tubing.

Making the cut.

Printed out spreadsheet of all the tubing sizes and lengths and how many of each. Used calculator to figure out the best cutting to minimize scrap.

A pile of 5/8" tubing cut and labeled.

Leftover 5/8" tubing from 2- 24' lengths of tubing.

Cut tubing with fishmouth template taped on and tubing ground down to guideline.

Another picture of fishmouth.

This is the set-up used on the drill press to drill the holes in the torque tubes.

Drilled a small hole in 3 hold down blocks on the center of the tube to guide the drill press when drilling the holes in the torque tubes.

The torque tube was cut a little long so that a 1/8" hole could drilled into the end for a screw to hold the tubing in position on the 2x2 while the other holes were drilled.

Torque tube srewed to 2x2, guide block in place, ready for drilling of the 3/8" hole. A centering drill bit was used first to start the holes.

These are the torque tube blocks made out of 3/4" thick sheet. Used the radial saw with the metal cut-off blade. 3/4" hole is drilled for the torque tube after the blocks are cut-out and bolted together.

Printed out part in AutoCad to make a template. Had to use drill press to drill holes along the inside curve, then knock it out and grind smooth.

Using a template printed out from the CAD drawing of the rudder horn the outline is transfered to a sheet of 1/8" 4130 sheet steel to be cut-out.

Parts for the aileron control assembly.

Rudder pedal parts cut and ground to shape.

Cut out the peice as much as I could with the radial saw then ground down to the guide line with the bench grinder

Checking the cut part against the drawing.

This is how I cut the angles. Used the radial saw set at 45 Deg.and a small drill press vice to hold the rectangular tube.

Making the cut.

Cut a peice of scrap 1/16" steel the size of the inside of the hinge assembly to hold the parts while being tacked together. The washer underneeth holds the metal in the center of the tubes.

1/16" metal and washer screwed to bench and hinge parts clamped in position to be tack welded.

Used peice of 1/16" welding rod to hold tubing for hinge in position on top logeron for welding.