Construction of the Cutting Bar

Construction of the Cutting Bar
Step 01: From the 1/8 inch aluminum stock, cut two 1 and 1/2 inch square brackets. Drill and countersink holes (9/64) in all of the corners 5/16 of an inch in from both directions.
	Step 02: From the 1/2 inch aluminum trim channel, cut two pieces 22 inches long.
Step 03: Using the head of the Toyo glass cutter as a spacing gauge (.20 thickness), clamp the two pieces of 1/2 inch trim together and place the square brackets on both ends of the the assembly.
NOTE: In the next few steps you will be drilling and boring out holes in the cutting arm assy thus far. It is important to keep in mind that the holes drilled are intended to go an equal distance on both sides of the trim channel.
	Step 04: Mount the brackets to both ends of the cutting arm using #6x32x3/8 slotted countersunk screws, nuts, and lock washers. Step 05: Drill a 5/16 inch hole in the center of ONE of the brackets only. This will be the end that pivots.
Step 06: Drill another 5/16 inch hole 18 1/8 inches up the arm from the center of the first hole.

	Step 07: For this step, it will be necessary to bore out the 5/16 inch holes previously drilled to 3/8 inch ON THE BOTTOM SIDE OF THE CUTTING ARM ONLY. Leave the hole in the mounting bracket 5/16 inch. I used a drill press and vise. With everything held securely in place, I was able to safely grind out the hole that will accommodate the spring used in the next step.
This is what the hole should look like after it has been bored out to 3/8 inch.
	Step 08: Insert the 5/16 x 1/2 bushing into the top side of the cutting arm, turn the arm over and install the 3/8" x 1" spring into the hole and around the shaft of the bushing.
Step 09: Install the bushing and spring (in the same manner) for the other hole.
	The cutting arm should now look like this.
The final step in the cutting bar assy is adding the tubing that is used to hold the glass in place while cutting.
Step 10: You will need two pieces of 3/8" ID x 1/2" OD vinyl tubing 15 inches long.

Step 11: Run a bead of silicon adhesive to the inside bottom of each channel the length of the tubing. Insert the tubing into the channel as shown below.

Step 12: Secure the assy to a flat surface in such a way as to hold the tubing straight and in place while the silicon is setting up. I clamped the assy in place and let it set for 24 hours before moving.
The construction of the cutting arm is now complete.
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This page or any code or content contained within, may not be linked or published elsewhere without express permission of the author. Author: Phillip D. Speed Copyright © 2001 [Pane In The Glass]. All rights reserved. Revised: June 24, 2006 .