Cutting Aluminum Booms

KRMx02 Making Aluminum Booms

I needed to reduce the weight of three aluminum booms for a Y6 Hex-copter I am working on. The booms are made from 1" square aluminum stock. The plan is to remove some of the material from the boom by cutting slits and holes into the sides and top. This would will reduce the weight while still keeping the structural rigidity of the square tube. . . .