How to make a bracket

[birdus]

I don't have experience working with metal and have had difficulty finding anything that talks about making brackets (e.g., where the wings or landing gear bolt onto the plane). Obviously, I can't use my tin snips to cut out the shape (metal's too thick), so my idea is to trace out the shape on my sheet of steel and use my soon-to-be-purchased DHC-2000 torch to cut out the shape (it's supposed to be quite precise at cutting), then just smooth the edges on my oscillating spindle sander. Maybe some filing, first, if my freshly cut metal lacks precision.

So here are my questions:

• Is my basic idea sound?
• What's the best way to get the shape from the paper plans drawn onto the metal?
• Is any kind of heat treatment necessary after the cutting process?
• As I understand it, any scratches on the metal are basically stress risers. What would be the best way to get the final, smooth finish onto the bracket?
• Anything else?

Thanks!
Jay

 

[Hot Wings]

 

[Dana]

 

[akwrencher]

 

[cheapracer]

 

[akwrencher]

 

[birdus]

 

[birdus]

 

[Matt G.]

 

[proppastie]

 

[akwrencher]

 

[clanon]

 

[Jay Kempf]

 

[proppastie]

 

[Jay Kempf]

 

[VAPORTRAIL]