For an upcoming project I would like to make some miniature structural shapes. For example an I-beam (or RSJ) 0.321in x 0.714in x 15.5in long. The project needs some other sizes too. But my question is what would be the best/easiest process to make these shapes that could be accomplished by a home shop?
Should I get stock and machine out material from both sides with a ball end mill to make the I shape? If I do it this way I'm afraid that the stock might warp badly. Especially if I try to make mini C-channel or angle and mill from one side only.
Perhaps instead use 3 pieces of flat stock and try to silver solder it together? With this idea i'm afraid I won't get it square and would probably have to heat/solder it in sections down its length because I only have a MAPP gas torch. Not sure what this would do to the integrity of the entire joints.
Or maybe someone has a better idea on how to go about making stuff like this? Oh and, I'm undecided on whether to use brass or steel too. I'm leaning toward steel for its strength and cause it's cheaper. If there is a good solution but with would only work with Aluminum I could use that as well. I'm just in the planning stages at the moment. Any suggestions?
Should I get stock and machine out material from both sides with a ball end mill to make the I shape? If I do it this way I'm afraid that the stock might warp badly. Especially if I try to make mini C-channel or angle and mill from one side only.
Perhaps instead use 3 pieces of flat stock and try to silver solder it together? With this idea i'm afraid I won't get it square and would probably have to heat/solder it in sections down its length because I only have a MAPP gas torch. Not sure what this would do to the integrity of the entire joints.
Or maybe someone has a better idea on how to go about making stuff like this? Oh and, I'm undecided on whether to use brass or steel too. I'm leaning toward steel for its strength and cause it's cheaper. If there is a good solution but with would only work with Aluminum I could use that as well. I'm just in the planning stages at the moment. Any suggestions?