Thatcher CX4 Flanging Dies

thingiverse

This is a set of flanging tools for the Thatcher CX4 aircraft. They are based on the dies shown in the Zenith Aircraft Construction Standards (http://www.zenithair.net/wp-content/uploads/pdf-doc/zenair%20construction%20standards%20draft%201-07.pdf). Inspiration was also drawn from the Sonex molded flanging dies (https://www.sonexaircraft.com/eshop/cart.php?target=product&product_id=16451). They should be printed out of PETG, which prints well, is very tough, and is very strong. I know these are pretty big prints, but they are still substantially cheaper than molded or turned dies. Even though it will take a long time, I suggest using the finest layer height in order to get good results on the fillets and chamfers. However, standard layer height will be fine. This is because light scuffing with 220 grit sandpaper is required to help smooth the flange surfaces. You don't have to use the alignment holes, but they will help keep things in place. I suggest placing the work in a vise using scrap wood on both sides and letting the vise do all of the work. I apologize for not having the pieces oriented properly for printing, but honestly, I'm too just lazy to fix them. I hold/maintain no liability for the use of these tools.